DG Flugzeugbau GmbHOtto-Lilienthal-Weg 2 / Am Flugplatz•D-76646 Bruchsal•GermanyPostbox 1480, D-76604 Bruchsal•DeutschlandTel. 07251/3020-100•Telefax 07251/3020-200•eMail: dg@dg-flugzeugbau.deSpare part and material sales: Tel. 07251/3020-270•lager@dg-flugzeugbau.dehttp://www.dg-flugzeugbau.deMAINTENANCE MANUALFOR THEMOTORGLIDERDG-808CType: DG-800AModel: DG-808CGerman Data Sheet No.: 873Factory Serial No.: __________________________Registration No.: __________________________Date of issue: June 2005Maintenance Manual DG-808CIssued: April 2009 TN800/35 0.10General0.1Manual amendmentsNo. Page Description Date1 0.3, 0.6, 0.10, 1.11, 8.2,diagrams 5a, 11d,8EP210ÄM 800-17-07Fin tank valve and operating handle,Refuelling pumpApril 20072 0.3, 0.4, 0.6, 0.7, 0.10,0.12, 1.28, 1.29, 2.7,3.3, 3.5, 3.11, 4.2, 4.8,4.11, encl. 2 page 1,TN 4600-2-2 SoloTN800/34Manual revisionSeptember20073 0.6, 8.1, diagram 10TN800/35Extension-retraction unit, rear fork ofspindle-driveApril 2009Maintenance Manual DG-808CIssued: September 2007 TN800/34 0.2This page was intentionally left blank.Maintenance Manual DG-808CIssued: September 2007 TN800/34 0.30.2List of effective pagesSection page issued replaced/ replaced/ replaced/0 0.0 June 20050.1 see manual amendments0.2 "0.3 "0.4 "0.5 "0.6 "0.7 June 2005 Sept. 20070.8 "0.9 "0.10 " Sept. 20070.11 "0.12 " Sept. 200711.1 June20051.2 "1.3 "1.4 "1.5 "1.6 "1.7 "1.8 "1.9 "1.10 "1.11 " April 20071.12 "1.13 "1.14 "1.15 "1.16 "1.17 "1.18 "1.19 "1.20 "1.21 "1.22 "1.23 "1.24 "1.25 "Maintenance Manual DG-808CIssued: September 2007 TN800/34 0.40.2 List of effective pages (continued)Section page issued replaced/ replaced/ replaced/1.26 "1.27 "1.28 " Sept. 20071.29 " Sept. 200722.1 June20052.2 "2.3 "2.4 "2.5 "2.6 "2.7 " Sept. 200733.1 June20053.2 "3.3 " Sept. 20073.4 "3.5 " Sept. 20073.6 "3.7 "3.8 "3.9 "3.10 "3.11 " Sept. 200744.1 June20054.2 " Sept. 20074.3 "4.4 "4.5 "4.6 "4.7 "4.8 " Sept. 20074.9 "4.10 "4.11 " Sept. 20074.12 "4.13 "4.14 "4.15 "4.16 "Maintenance Manual DG-808CIssued: June 2005 0.50.2 List of effective pages (continued)Section page issued replaced/ replaced/ replaced/4.17 June 20054.18 "4.19 "4.20 "4.21 "4.22 "4.23 "4.24 "4.25 "4.26 "4.27 "4.28 "4.29 "4.30 "4.31 "4.32 "4.33 "4.34 "4.35 "4.36 "4.37 "4.38 "4.39 "55.1 June20055.2 "66.1 June20056.2 "6.3 "77.1 June20057.2 June200588.1 June2005"8.2 "8.3 "8.4 "9 9.1 June 20059.2 "Maintenance Manual DG-808CIssued: April 2009 TN800/35 0.60.3List of effective pages (continued)diagram page issued replaced/ replaced/ replaced/1 June 20052 June 20053 Nov. 20044 Nov. 19935 Nov. 2004 Not valid from 8-373 on5a April 076 May 20057a August 20057b August 20058 August 20059 August 200510 August 2005 April 200911 Juni 2005Not valid from 8-373 on11c June 199911d April 0712 June 200513 Febr. 199914 Nov. 200414a June 200515 Nov. 200416 Nov. 20046EP27M 28.08.908EP38 17.02.998EP210 10.10.04 12.02.078M110 23.10.028M234 25.08.058V96 19.12.94W40 30.11.99W51 20.11.96W57 10.09.99W59 18.06.02W60 25.10.048E25 25.06.998E210 15.05.978E250 13.09.058E256 24.06.05Encl. 1 June 2005Encl. 2 June 2005TN 4600-2-2 SoloJan. 2007Maintenance Manual DG-808CIssued: September 2007 TN800/34 0.70.4List of contentpage0General 0.10.1Manual amendments .............................................................................. 0.10.2List of effective pages............................................................................ 0.30.3List of content ........................................................................................ 0.70.4Airworthiness limitations..................................................................... 0.111System description and adjustment data1.11.1Wing and tailplane setting data.............................................................. 1.11.2Elevator control and trim system ........................................................... 1.21.3Rudder control........................................................................................ 1.51.4Aileron and wing flap control................................................................ 1.61.5Airbrake control, wheelbrake................................................................. 1.81.6Undercarriage......................................................................................... 1.91.7Tow hooks............................................................................................ 1.101.8Water ballast system ............................................................................ 1.111.9Massbalance and weights of control surfaces...................................... 1.121.10Fore and aft play of the wings.......................................................... 1.131.11Power Plant ...................................................................................... 1.141.12Retraction - Extension Mechanism.................................................. 1.171.13Fuel system ...................................................................................... 1.181.14Electrical system .............................................................................. 1.231.15 Pitot and static system1.29Maintenance Manual DG-808CIssued: June 2005 0.82Inspections 2.12.1Daily inspection ..................................................................................... 2.12.2Regular inspections................................................................................ 2.12.3Inspections after a heavy landing........................................................... 2.32.4Inspection procedure for increase of service time ................................. 2.62.5Inspection procedure for the controls .................................................... 2.73Maintenance 3.13.1General maintenance.............................................................................. 3.13.2Maintenance of the airframe .................................................................. 3.23.3Greasing and oiling ................................................................................ 3.33.4Damage of the airframe ......................................................................... 3.43.5Servicing the Engine .............................................................................. 3.54Detailed instructions for assembly and servicing work4.14.1Water-ballast system (only Version Classic)......................................... 4.14.2Replacement of control circuit cables.................................................... 4.24.3Adjustment and servicing of the control circuit..................................... 4.24.4Removal and installation of the undercarriage (main wheel)................ 4.34.5Fixing excessive free play of the canopy............................................... 4.64.6Removal and installation of the flaperons ............................................. 4.74.7Control surface seals and turbulators..................................................... 4.84.8Determination of the moments of the flaperons .................................. 4.124.9Working instructions for heat-shrink tubing........................................ 4.134.10Securing with Loctite....................................................................... 4.13Maintenance Manual DG-808CIssued: June 2005 0.94.11Replacement of wing fuel tanks (Option)........................................ 4.144.12Mounting and tensioning of the drive belt....................................... 4.154.13Replacing the bearings of the upper drive belt pulley ..................... 4.184.14Removal and installation of the tension gas-strut............................ 4.204.15Replacement of the engine retaining cable...................................... 4.214.16Filling and bleeding the cooling system .......................................... 4.224.17Installation and removal of the powerplant ..................................... 4.244.18Removal and assembly of the engine doors..................................... 4.314.19Securing the propeller bolts ............................................................. 4.324.20Checking the Ignition unit type Ducati............................................ 4.334.21Installation and removal of the extension/retraction unit ................ 4.364.22Calibration of the fuel display in the DEI-NT ................................. 4.374.23Further DEI-NT settings .................................................................. 4.375Weight and balance5.16Instrumentation and accessories list6.17List of special tools7.18Partlist 8.18.1Parts for the powerplant......................................................................... 8.18.2Parts for the electrical system ................................................................ 8.38.3Control surface sealings and turbulators................................................ 8.49Enclosures 9.19.1Equipment list ........................................................................................ 9.19.2Checklist for checks and maintenance work.......................................... 9.2Maintenance Manual DG-808CIssued: September 2007 TN800/34 0.10Diagrams1 Elevator control circuit, trim2 Rudder control circuit3 Aileron, wing flap and airbrake control circuits, fuselage side4 Flaperon and airbrake control circuits, wing side5 Tow hook, water ballast system5a Tow hook, water ballast system from ser. no. 8-373 on6 Static and pitot system7a Placards DG-808C Classic7b Placards DG-808C Competition8 Powerplant9 Cooling system10a Extension-retraction mechanism11 Fuel system11c Installation of the fuel filter11d Fuel system from ser. no. 8-373 on12a Tailwheel13 Propellerbrake14 Engine doors and retaining cable14a Retaining cable mounting in fuselage15 Undercarriage control circuit16 UndercarriageEnclosures6EP27M Installation Dräger oxygen system8EP38 Installation plan ELT ACK8EP210 wing fuel tank system fuselage side with electromagnetic valves8M110 Drawing assembly upper drive belt pulley8M234 Ext.-retr. unit, installation propeller stopper Option BBSA clutch8V96 Drawing jigs to determine the static moment of the flaperonsW40 Puller assy. for lower drive belt pulleyW51 Drawing hook spanner for bearingsW57 Tool for measuring the drive belt tensionW59 Test adapter for coolant pump testW60 Puller assy. for lower drive belt pulley Option BBSA clutch8E25 Wiring plan wing fuel tank system fuselage side with electromagneticvalves8E250 Wiring plan DIN A1 (in aircraft log)8E256 Wiring scheme8E210 Extension wires for checking the ignition electronic boxesEncl. 1 Download instruction for flightlog and service data from the DEI-NTEncl. 2 Instructions for transponder installationTN 4600-2-2 SoloCheck and modification of the slip-clutch on the engines 2 625 01 and 2625 02Maintenance Manual DG-808CIssued: June 2005 0.110.5Airworthiness limitations0.5.1RepairsRepair or replace damaged parts prior to next flight. Follow the instructions ofthe DG-800B repair manual for repairs of the airframe. Repairs outside thescope of DG-800B repair manual and major repairs must be accomplished at acertified repair station or by a certified mechanic rated for composite aircraftstructure work in accordance with DG repair methods.Use only genuine spare parts.0.5.2Life time of the airframeThe maximum allowable operating time for composite sailplanes is 12000 flighthours. Therefore inspections according to section 2.4 of this manual have to beexecuted at 3000 h, 6000 h, 9000 h and every 1000 hours following thereafter.0.5.3Life time of componentsa)The followingcomponents of the power planthave to be replaced after400 engine hours.1.All nuts and bolts on the engine2.The bearings of the upper drive belt pulleyb)The gasket for the drainer valvehas to be exchanged after 6 years.c)Thehoses of the cooling systemhave to be ex-changed after 6 years.d)The 2 upperrollers for the drive belthave to be exchanged every 50 enginehourse)Drive belt:Without optional BBSA friction/centrifugal clutch: The drive belt has to beexchanged after 50 engine hours.With optional BBSA friction/centrifugal clutch: The drive belt has to beexchanged after 100 engine hoursf)Thespark plugshave to be exchanged after 25 engine hours.g)Thefabric straps of the safety harnesshave to be exchanged after 12years.h)Other componentsAll other components like tow hook, wheels, gas struts, control system parts,bolts, pins etc. have no life time limitation, but should be replaced whenworn, damaged or disqualified by excessive corrosion.i)Flexible fuel bags in the wings (option)Type Uniroyal (rubber): these will have to be exchanged after 10 years.Maintenance Manual DG-808CIssued: September 2007 TN800/34 0.120.5.4Service time, maintenance documentsFollow the instructions of the respective manufacturer:a)Operating Manual for Safety Tow ReleasesSeries: Europa G 88 Safety Tow ReleaseDate of Issue: February 1989And if installed:Operating Manual for Tow ReleasesSeries: E 85 Nose Tow ReleaseDate of Issue: March 1989b)Safety harness: instructions of the manufacturer.c)Minimum instrumentation: instructions of the manufacturer.d) Engine: Manual of the engine manufacturere) Propeller: Technoflug Operation and maintenance manual No. P3.0.5.5Power plant trouble shootingPlease find a checklist in the DG-808Cflight manual section 8.8.Note:The Airworthiness Limitations section is FAA approved and specifiesmaintenance required under Secs. 43.16 and 91.403 of the Federal AviationRegulation unless an alternative program has been FAA approved.LBA approvedMaintenance Manual DG-808CIssued: June 2005 1.11System description and adjustment data1.1Wing and tailplane setting dataWing:Sweep back (Leading edge): 0 +3 mm (+0.12 in.) at wing taper changeDihedral (Leading edge line): 2.5° = 196 mm (7.72 in.) at wing taperchange (y = 4.5 m)Angles of Incidence: -1° measured at wing flap setting -5°Horizontal tailplane:-3,5°chord linesfuselage centre line(corresponding to boom slope 1000:37)Wing oscillationfrequency:approx. 160/min 15 m span with wingletsapprox. 130/min 18 m span without partingapprox. 124/min 18 m span with parting andwingletsAircraft should rest on both wheels during frequency measurements.1°3,5°Maintenance Manual DG-808CIssued: June 2005 1.21.2Elevator control and trim system1.2.1Control systemsee diagram 11.2.2Elevator deflections and tolerancesup:46 +2 mm 1.81 +0.08 in.down:46 +2 mm 1.81 +0.08 in.measured at 134 mm (5.3 in.) from hinge axis which is directly at the edgeof the cut-out for the rudder.Measurement:Hold a measuring stick with one end on the floor. Deflect the elevator to neutralposition by bringing the mark at the sealing in line with the upper end of the fin.Mark the 0-point on the stick. Then mark the up and down displacement.measuring stick one end on the floor46±2 mm46±2 mmsealingmarkMaintenance Manual DG-808CIssued: June 2005 1.31.2.3Elevator stopsThe elevator stops are located at the base of the control column and can beadjusted with a 10 mm open ended spanner.1.2.4Elevator control circuit free playWith the elevator held fixed at the 0 point, the free play at the top of the controlcolumn can be +1.5 mm (+0.06 in.). Within the automatic elevator connectionthere should be no free play noticeable when the elevator is moved at its trailingedge.Any free play can be reduced by screwing in the adjustment screw on theautomatic connector funnel.1.2.5TrimThe automatic trim mechanism should be adjusted according to the sketchbelow. The measurements a and b are with the control stick in forwardposition: a = 30 mm (1.18 in.),b = 187 mm (7.36 in.), c = 357 mm (14.1 in.).The bungee interconnection between wing flap lever 8S 9 and trim lever 2St32is to be replaced, when worn or when elongated. The length in unstretchedcondition y must be 110 mm (4.3 in.). The interconnection consists of 2 mmdiameter. bungee wound around 3 times.locking nutadjustment screwelevatory6St92St322St32a bcbulkheadMaintenance Manual DG-808CIssued: June 2005 1.41.2.6Repair of the automatic trim mechanism Bowden cableIn the event of a replacement Bowden cable being installed, it should beemphasised that the cable must pass between the two parallel arms of theControl column mechanism as shown in the sketch.correctwrongIf the cable passes outside the mechanismcontrol column movement can beblocked.Maintenance Manual DG-808CIssued: June 2005 1.51.3Rudder control1.3.1Rudder control circuitsee diagram 21.3.2Rudder deflections and tolerances155mm (6.5 inch) (28°) +0, -5mm (-.2 inch) measured at 318 mm (12.52 inch)from the hinge axis.1.3.3Rudder stopsThe rudder stops are located at the lower hinge pedestal and can be adjustedwith an Allen key wrench.1.3.4Axial free PlayThe maximum allowable free play at the upper hinge point is 1.5 mm (0.06 inch)1.3.5Sealing the rudderThe rudder is sealed on both sides. On the outside with Mylar combi-tape andinside the fin with V-sealing tapesThese sealings are not to be removed.If damaged it should be replaced, see section 4.7.5max. 1,5 mmMaintenance Manual DG-808CIssued: June 2005 1.61.4Aileron and wing flap control1.4.1Control circuitsee diagrams 3 and 4A spring at the mixer shaft 8St70 provides additional aileron return force atpositive wing flap settings.Note:The bearing of 6St9 on 6St15 see diagram 3 must not be greased (Teflonbearing).1.4.2Deflections and tolerancesAileron deflections: up 42 ± 3 mm 1.65 +0.12 in.down 21 ± 3 mm 0.83 +0.12 in.measured at 122 mm (4.8 in.) from hinge axis (at inboard end), wing flapsetting 0°.Wing flap deflections: up -14° 19 ± 3 mm (-0.75 +0.12 in.)down L 38 ± 3 mm +1.50 +0.12 in.)measured at 122 mm (4.8 in.) from hinge axis against the fixed part at the wingroot.At flap setting -5° the flaperons have to be adjusted against the fixed part at thewing root with 0 +1 mm (0 +0.04 in.).1.4.3StopsThe aileron stops are located behind the removable left-hand side panel. Thestops can be adjusted at the nuts on the pushrod with two 4 mm (5/32 in.)diameter rods or drills.The wing flap stops are located at the pushrod 6St8.The stop for the positive setting (welded washer at pushrod 6St8 withNylonbush) is at the seatback bulkhead. Adjustment by displacing pushrod 6St8against the rear pushrod 6St7.The stop in negative setting is a hose clamp which stops at the leaf-spring 8St4.1.4.4Free playThe max. free play measured at the trailing edge of the flaperons measured at122 mm (4.8 in.) from hinge axis should not exceed +1 mm (+0.04 in.) Thecontrol stick and the wingflap should be in neutral position.For the measurement fix the flaperon of the opposite wing. With both flaperonsfixed, a maximum free play of +1.5 mm (+0.06 in.) at the top of the control stickis allowed.Maintenance Manual DG-808CIssued: June 2005 1.71.4.5Complete readjustmentShould it be necessary to completely reset the flap and aileron control, proceedas follows:Place the fuselage with the centre line horizontal see sect. 1.1. Fix the mixershaft 8St70 (see diagram 3) in horizontal position.then:1. Adjust the control stick to neutral.2. Adjust the wing flap handle to 0° flapsetting.3. Adjust the flaperons: + 10.6 mm (0.42 in.) measured against the fixed part atthe wing root and + 4.1 mm (0.16 in.) against the 18 m wing tip.To adjust the flaperons you must first remove the fairings from the controlsurface horns. Then unscrew the horns (Allen key wrench) and loosen the locknut (12 mm open ended wrench) at the rod ends. Adjustment is made by rotatingthe complete drive.Note:Secure the bolts again with a small amount of Loctite 243.4. Adjust the aileron stops. (See 1.4.3)5. Check the flap deflections and adjust the stops if necessary. (See 1.4.3)6. Glue the fairings to the control surface horns with Polyester resin. Applypressure when gluing to prevent the fairings interfering.horizontal8St70Maintenance Manual DG-808CIssued: June 2005 1.81.5Airbrake control, wheelbrake1.5.1Control circuitsee diagrams 3 and 4)The wheelbrake cable is connected to the airbrake torsion shaft (part 8St12).1.5.2Adjustmenta) Airbrake overcentre locking force. Adjust the airbrake rod in the airbrakebox so that both airbrakes retract evenly and that the overcentre lockingforce on the airbrake operating handle is between 15 - 20 daN (33-44 lbs.).Adjustment can be done with a 13mm open end spanner.b) Airbrake extension height. The height the airbrakes extend depends on thewheelbrake adjustment.c) Wheel braking force.Drum brake: With insufficient braking effect, the wheel- brake can beadjusted by a screw on the end of the Bowden cable housing, located on theforward undercarriage fork above the brake actuating lever.Hydraulic disc brake: Adjustment is at the turnbuckle between main brakecylinder and airbrake control shaft.d) The airbrake control has to be adjusted, so that with the airbrakes fullyextended (rear stop at the seat back bulkhead) the wing flap handle will bemoved to a position 10 mm (.4 in.) aft of the +5° notch. Adjustment at therod ends of the pushrods 6St13 and 6St14/1.Check the total travel. (See 1.5.3)1.5.3Airbrake stopsThe rear airbrake control circuit stop is located at the seat back bulkhead. Thetotal travel must be min. 215 mm (8.46 in.). For adjustment, see above. Thestop, in locked direction, is situated at the wing rootribs. The corresponding stopat the guide rod St11a/2 in the cockpit should be placed to allow a free play of 0-3 mm (0-.12 in.) between the airbrake handle and the stop at the guide rod withthe airbrakes locked over centre.1.5.4Free playFree play in the airbrake control system is of no effect.The airbrakes themselves at their hinges should not have so much free play thatthey hit the wing surface instead of entering into their boxes during retractionunder airloads.Maintenance Manual DG-808CIssued: June 2005 1.91.6Undercarriage1.6.1Main undercarriage1.6.1.1Undercarriage control circuit see diagram 15, undercarriage seediagram 161.6.1.2Adjustmenta) Should the undercarriage not retract fully, an adjustment can be madeby screwing out the universal rod end on pushrod 8FW47 with a 13 mmopen end spanner.b) The lock, in extended position, is by means of the gas strut on thelanding gear box and additionally by a locking rubber buffer in thecockpit. The clearance between the locking latch at the handle and thefront end of the rubber buffer should be 0.5 to max. 1 mm (.02 to max..04 in.) with the spring suspension of the undercarriage fully extended.Adjustment can be made at the mounting of the rubber buffer.A torsion-spring is installed to keep the handle in the locked position.1.6.1.3Free playFree play between lever 8FW42 and the upper strut 8FW40/1 is notallowed. If there is any free play, the two securing bolts M 6x40 shouldbe tightened with a 10 mm open end spanner. If there is still some freeplay, the bolts should be removed and the holes drilled out and reamedto diameter 8 H7. M 8x40 LN 9037 bolts should then be installed.1.6.2Tailwheel1.6.2.1The steerable tailwheel is connected to the rudder via two tensionsprings, the tailwheel-fork is mounted on needle bearings, see diagram12a.1.6.2.2Disassembly of the tailwheel fork1. Remove the tailwheel2. Loosen the M 5 nut (8mm spanner)3. Release the springs4. Draw the fork out while displacing it sidewards.1.6.2.3The tailwheel axle must always be fixed tight.1.6.3Tyre pressuremain wheel 3 bar 43 psitail wheel 2 bar 29 psiMaintenance Manual DG-808CIssued: June 2005 1.101.7Tow hooks1.7.1Tow release circuitsee diagram 51.7.2AdjustmentThere should be 5 +2 mm (.2 in. +0.08 in.) space between the tow release knoband the nylon cable guide.5±21.7.3DamagesThe ring muzzle of the C.G. hook should not be bent or ground down and moveeasily. If the muzzle is damaged, the tow release has to be exchanged andrepaired by the manufacturer (Tost).1.7.4Removing the tow hooksThe tow hooks are to be removed in upward direction (use a piece of hard woodand a hammer). Be careful not to break loose the seat shell with the C.G. towhook.1.7.5Operating and maintenance instructionsFor further information refer to the operating and maintenance instructions forthe release mechanism. (See sect. 0.4 of this maintenance manual)Maintenance Manual DG-808CIssued: April 2007 ÄM 800-17-07 1.111.8Water ballast system1.8.1Water ballast release circuitsee diagram 51.8.2Wing tanksVersion DG-808C Classic: double wall bags with a capacity of 50l per wing.Version DG-808C Competition: double wall bags with a capacity of 60l (15.85U.S. gal) or 75l (19.8 U.S. gal) per wing. The 75l waterbags are separated in 2chambers. A check-valve is located between the 2 chambers. Operating thewaterballast system without the check-valves is prohibited.a)AdjustmentFor the dump valve in the closed position, there should be 1 mm (.04 in.)space between the 8 mm (.315 in.) diameter PVC rod from the dump valve,and the plate lever on the fuselage. Adjust at the adjustment screw located atthe fuselage wall. If this is insufficient, the 8 mm PVC rod can be shortened.If a valve still leaks, then the rubber gasket and the associated spring at theend of the 8mm PVC rod should be loosened, pressed further in and securedagain. If this is not successful, the valve ball seat should be greased. (seesect. 4.1)b)Servicingsee section 4.1.1.8.3Fin tank (only version DG-808C Competition)The fin ballast tank is constructed as integral tank.a)AdjustmentThe release cable must be adjusted so that the cable just becomes loose whenthe handle is parallel to the fuselage wall.b) InspectionAccording to sect. 2.2 a special inspection is to be carried out on the finballast tank system at each annual inspection.The dump time of the full fin tank should be timed and should not exceed120 seconds.Check the calibration of the outside air temperature gauge (in the DEI-NT).Up to ser.no. 8-372:Remove the tailwheel and the cover plate in thetailwheel box. Check the control cable and the lever of the valve carefullyfor wear. Check the control cable at the operating handle too. If the cable orthe lever is worn, further use of the fin tank is prohibited. Please contact themanufacturer for a detailed repair instruction.From ser. no. 8-373 on:Check the control cable at the operating handle andat the dump valve (installed in the lower rudder mounting bracket). If thecable is worn, further use of the fin tank is prohibited.Maintenance Manual DG-808CIssued: June 2005 1.121.9Massbalance and weights of control surfacesAfter repairs or repainting the control surfaces weights and momentsshould not exceed the following limits.Control Weight Moment Spring balancesurface reading seeinstructions belowkg kg cm kg(lbs.) (lbs.in.) (lbs.)max. min. max. min. max. min.Rudder 2.45 2.05 4.5 3.12 0.225 0.156(with massball.) (5.40) (4.52) (3.91) (2.71) (0.495) (0.343)Elevator 1.52 1.2 3.92 3.08 0.293 0.230(without pushrod) (3.35) (2.65) (3.40) (2.67) (0.646) (0.507)without wing partingFlaperon 5.71 3.60 10.99 9.27 0.900 0.760(12.59) (7.94) (9.54) (8.05) (1.984) (1.676)with wing partingFlaperon (inboard 5.14 3.50 10.37 8.66 0.850 0.710wing) (11.33) (7.72) (9.00) (7.52) (1.874) (1.566)Flaperon 0.57 0.45 0.693 0.55 0.105 0.083(wing tip) (1.26) (0.99) (0.60) (0.48) (0.231) (0.183)Note:Before any changes to the massbalance weights are made, contact the DGFlugzeugbau factory.Method for determining control surface momentsAll control surfaces: Remove the control surface and hang it friction free on twohinge points.It is important that flaperons and elevator are positioned upside up.The elevator must be hung at hinges 2 and 5.Flaperon: Use the procedure described in sect. 4.8.Control surfacemeasuring point distance behindhinge line (mm)Rudder lowerend 2007.9in.Elevatorcentre, y=70mm(2.76 in.)134 5.3 in.Flaperon inboardflaperon root 122 4.8 in.Flaperon 18m wing tip flaperon root 66 2.6 in.Maintenance Manual DG-808CIssued: June 2005 1.131.10Fore and aft play of the wings1.10.1At the fuselagea)With the aircraft fully rigged, move the wings fore and aft to determine atwhich lift pin the most play exists.b)Derig the glider.c)Screw out the lift pin and insert a distance washer (inside diameter16.5 mm(.65 in.)) and screw in the pin again. Tighten the lift pin.d)Rig again and check the free play.1.10.2At the wing tip joint(option)a)Check see above.b)Roughen the area around the lift pin and attach a distance washer insidediameter 10.5 mm (.41 in.) 0.25 mm (0.01 in.) thick with a suitable metaladhesive (e.g. Stabilit Express). Note the total thickness of the washers at theroot rib with a waterproof marker pen.c)Rig the wing tips again and check the free play.1.10.3TolerancesFree play should be adjusted if you hear a rattling sound when moving the wingsbackwards and forwards. The max. amount of free play can also be determinedas follows: Measure the free play at each lift pin with a feeler gauge. Sum up thefree play.At fuselage: The free play of all 4 pins together should not exceed 0.5 mm.At the wing tip joint: The free play of the 2 pins together should not exceed0.5 mm.Maintenance Manual DG-808CIssued: June 2005 1.141.11Power Plant1.11.1Arrangement:see diagrams 8 and 9.You will find a part list with the designations and the referencenumbers for the powerplant parts at the end of this manual.1.11.2Engine:Theengineis a SOLO 2625 01 with electronic dual ignition and liquidcooling. For further engine specifications refer to the engine manual,see sect. 0.4 of this manual. The cooling circuit is equipped with anelectric waterpump. The pump operates with ignition on. If the gliderelectrics are switched off (master switch) with running engine, thepump will still receive electric power from the generator.Coolant: 1 part glycol and 1 part distilled water (up to approx. –40°C,40°F)Caution:If you don't operate the engine for periods longer than 2months you must preserve your engine according to the instructions inthe engine manual. The same applies for any overseas transportation.1.11.3Exhaust Muffler:The muffler has been specially designed for the DG-800B and isattached by four spring couplings in a movable frame, secured withLoctite 243.1.11.4Propeller:KS-1G-152-R-122-( )-B, attachment bolts: - six M 8 x 65 DIN 931 -8.8, head with a 2 mm (0.08 in.) dia. hole for lockwiring. Tighteningtorque of the bolts - 2-2.5 daNm (15-18 ft lb).Propeller positioning(not with optional BBSA friction-centrifugalclutch):To assist in having the propeller stop in a vertical positionduring flight, the propeller should be positioned accordingly to thecompression point of the engine. With the propeller in the position forretraction the magneto flywheel must be in the following position:x= approx. 20mm (.79in.) with theactuator directly above the centreof the proximity switchAdjustment is made slipping thedrive belt into the required position.view fromthe rearxMaintenance Manual DG-808CIssued: June 2005 1.151.11.5Drive Belt:Type of drive belt see section 8.1.Drive Belt Tensioning:The drive belt should not be loose. Tensioning adjustment can be madeby turning the eccentric propeller shaft, see sect. 4.12g.As Option a BBSA friction-centrifugal clutch may be installed toreduce the drive belt loads when starting the engine. The clutch ismaintenance free and constructed as one unit together with the lowerpulley and the starter ring gear. With the clutch the propeller position tothe compression point of the engine will change every engine start, sofor aligning the propeller for retraction a stopper according to drawing8M234 (enclosed to the MM) is necessary.1.11.6Starter:Electric starter motor, type see section 8.1.1.11.7Ignition system:a)spark plugs;Electrode gap 0.5 mm (o.02 in.). Type see section 8.1.c)The electronic boxes (incl. ignition coils) are mounted at the propellermount (carbonfibre tower).1.11.8Throttle cable connectionsThe cable can be finely adjusted at the connection point just below thecarburettor. With fully open throttle (butterfly valve vertical) the cableshould be loose. The cable is 1.5 mm diameter Bowden-cableFriction device for throttle control: This device is located at the controlbellcrank in the instrument panel.The brake force must be adjusted for a control force of 15 - 50 N(3 - 11 lbs.).1.11.9Propeller brakesee diagram 13a)manual activation: The brake cable can be adjusted at theadjustment screw at the rear end of the engine.Maintenance Manual DG-808CIssued: June 2005 1.16b)electrical activation (Option): The electric brake-motor acts on thesame brake lever. Adjustment is similar to the manual brake and viaa second adjustment screw located directly at the brake motorwhich is mounted to the lower left side of the engine bay.With the brake off, there should be a clearance of at least 0.5 mm(.02in) between the brake pad and the magneto flywheel. The brake padshould be replaced when there is only 3 mm (.1 in) of pad left. The padhas to be glued on with UHU Plus 300. The glue must be cured for min.5 minutes at 180°C (356°F). Replacement pads: part no. 8M275/3.Or screw on brake pad with mounting bracket: part no. 8M287/3. Themounting bolts have to be secured with Loctite 243.1.11.10Tightening torques and locking:a) All bolts on the engine which are not secured by selflocking nutsshould be tightened according to the following:M 10 - 40 N m ( 29 ft lb)M 8 - 20 N m ( 15 ft lb)M 6 - 12 N m ( 9 ft lb)They should also be secured with Loctite 243. All locked and securedbolts are marked with red paint which also marks the respectivecomponent at that particular point. Whenever a bolt has to be tightenedor taken off, the red paint should also be removed and only renewedafter the bolt is once again securely attached with Loctite.b) Cylinder head nuts 20 N m (15 ft lb)CHT probe 15 N m (11 ft lb)spark plugs 20 N m (15 ft lb)propeller 20 N m (15 ft lb)magneto flywheel 80 N m (58 ft lb)lower drive belt pulley 100 N m (73 ft lb)1.11.11Fire warning lightThe probe is located at the engine bay side wall opposite to thecarburettor. There is a fuse 0.2 A for the „fire“ probe in the wiring nearthe engine master switch.To check its function a self-test- function is installed.When switching on the main switch the fire warning light must flashonce.Maintenance Manual DG-808CIssued: June 2005 1.171.12Retraction - Extension Mechanism1.12.1Layout see diagram 101.12.2The retraction-extension mechanism(spindle drive) consists of a 12 V electrically driven sealed trapezoidscrew shaft. A tension gas-strut is installed parallel to the spindle driveto compensate the engine weight.1.12.3Extension force of the gas-strutTime for extension approx. 11-13 seconds, time for retraction approx.10-12 seconds. If the extension takes much longer (4 seconds) then thegas-strut must be replaced. Measure at room temperature, with fullbatteries and via the ignition switch.1.12.4Adjusting the powerplant retaining cableExtend the engine via the ignition switch until the extension is switchedoff by the position switch.It should be possible in this position to pull out the retaining cableapprox. 15mm (.6 in.) before it comes to its stop. If necessary adjust viathe adjustment screw. Secure the adjustment screw by fastening its locknut.1.12.5Position switchesPosition engine retracted: via a switch actuated by the propellermountPosition engine extended: via a switch actuated by the muffler frame1.12.6Adjustment of the powerplant positionsPosition engine extended for operation:Extend the engine via the ignition switch until the extension is switchedoff by the position switch. The angleαmust be 91°. If necessary, theangle has to be corrected by bending the metal lever of the limit switch.αpropeller mountedge of engine bayMaintenance Manual DG-808CIssued: June 2005 1.18Position engine retracted:Retract the engine via the ignition switch. When the propellermounttouches the stop (at the upper part of the propellermount) thespindledrive should not be switched off, but should move thepowerplant backwards for another 5mm (.2 in.) before the positionswitch is actuated. This prevents the powerplant from moving upwardswith negative g-loads (flexibility of the rubber mounts).1.13Fuel system1.13.1Layoutsee diagram 111.13.2Tanks1.13.2.1Fuselage tankThe fuselage tank is permanently fixed and has 21 litres (5.55 US gal.)capacity which can be used down to at least 0.5 l (0.13 US gal.). Thetank can be drained via a drainer located in the landing gear box at itsrear wall. The tank can be flushed after removing the drainer. The ventoutlet of the fuselage tank is at the bottom of the fuselage.1.13.2.2Wing fuel bags (Option)In addition fuel bags may be installed in the wings, see section 1.13.9.After opening the respective valve the content of the bag can be drainedinto the fuselage tank.1.13.2.3RefuellingFilling the fuselage tank may be done with the installed electricrefuelling pump.A sensor (at the lower end of the fuel filler) switches off the electricpower to the pump when the fuel tank is filled completely andautomatically executes a calibration of the fuel gauge.Filling is also possible via the fuel filler opening on the fuselageexterior surface. No automatic calibration will be executed. A manualcalibration is possible see flight manual section 4.2.3.3.1.13.2.4Excess fuel lineClose to the carburettor an excess fuel line with built in restrictionseparates and runs back to the fuel tank.Maintenance Manual DG-808CIssued: June 2005 1.191.13.3Fuel pumpsElectric fuel pump mounted in the fuselage centre section. This pumpoperates as soon as the ignition is switched on. In case the electricpower is switched off via the master switch with running engine, thepump will receive electric power directly from the generator.Min. fuel flow at the electric pump: 40 l / hour (10.6 U.S.gal. /hour).The fuel flow can be determined by disassembling the fuel supply lineat the distributor near the carburettor and flowing 1 litre (.26 U.S.gal.)of fuel into a container. Max. time for 1 litre: 90 seconds. (Thefuselagetank should contain at least 10 l (2.6 U.S. gal.) of fuel for themeasurement). Should the flow rate be lower, then the filter could bedirty or there could be an obstruction elsewhere in the fuel system.In line to the pump described above, a second pump is installed. Thispump receives its electric power only from the generator, so it operatesonly with the engine running. It is protected by a separate fuse locatedin the control unit, so that this pump operates even with the main switchoff. Via a press button located in the instrument panel, the first pumpcan be switched off with the engine running to check the function of thesecond pump.The excess fuel line with built in restriction limits the fuel pressure .1.13.4Fuel cockThe fuel cock is mounted on the fuselage floor between the tank and theelectric fuel pump. The cock is controlled by a diameter 2 mm (0.08in.) piano-wire from the cockpit. The stops are located directly at thelever of the fuel cock.1.13.5Fuel filterThe filter is installed between fuel cock and electric fuel pump. Thefilter is visible in the baggage compartment.Warning:Use only a transparent filter, type see section 8.1.1.13.6Fuel quantity indicationThe fuel quantity measuring system in the fuselage tank is by condenserplates. The aircraft's attitude hardly affects the readout. Incorrectreadings can result if the condenser plates are dirty. A thoroughflushing of the plates and fuel tank should solve the problem. Asdifferent fuel qualities may result in different readings a calibrationshould be carried out each time the tank is filled completely, see sect.1.13.2.3.After replacement of the DEI-NT you have to execute a complete fuelgauge calibration according to sect. 4.22.Maintenance Manual DG-808CIssued: June 2005 1.201.13.7Carburettor1.13.7.1Type:Mikuni Membrane carburettor BN 38Instead of a choke a fuel injection (primer) is installed.Normal position of the fine adjustment nozzle is fully anticlockwise(open). For high altitude operation the nozzle may be turned inclockwise direction (closed).1.13.7.2CleaningTo clean the carburettor you should execute items 1 to 3. Switch on theignition to clean the carburettor by the electric fuel pump.If the carburettor is clean, a jet of fuel will spurt out. In addition, theopenings for idle and main nozzle have to be cleaned with compressedair.Warning:Don’t bend the lever which actuates the needle valve.1.Removal of the needle valve: Unscrew the carburettor cover andremove together with the membrane. Loosen the mounting screw andremove the lever, axle and needle valve as one unit. Be careful not toloose the return spring.Maintenance Manual DG-808CIssued: June 2005 1.212.Removal of the main nozzle:Loosen the 2 screws and lift off the cover plate with the rubber sealingScrew out the main nozzle.If it is necessary to remove the Tommy screw for cleaning you have tolift off the fine adjustment screw which covers the Tommy screw.Screw in the Tommy screw first to note the number of turns.3.Removal of the idle nozzle:Screw in the Tommy screw first to note the number of turns and theactual position of the lever ( 1 1/8 turn). Then turn out the Tommyscrew.In addition to the Tommy screw an idle nozzle must be screwed out.The nozzle is located in the same compartment as the main nozzlebelow the main nozzle.4.Reassembling:Screw in the Tommy screw(s) completely and then screw them out tothe noted positions.The membrane is to be positioned between the rubber and the metalcover plate. Use Loctite 243 to secure the screws of the carburettorcover. All measures should be executed carefully and cleanly.5.Carburettor setting:Adjust the idle RPM by the idle adjustment screw to approx. 2500RPM with warm engine.Note:With optional EGT probes the setting of the carburettor mainnozzles can be controlled by the EGT values. Set the nozzles to EGTvalues of 640°C +10°C on the ground at full power with the enginewarmed up. This value is valid with the fine adjustment screw open andfor the hotter of both cylinders at 100m above MSL. If the adjustmentis to be done at a higher altitude 2.5°C must be deducted from the EGTvalue per 100m altitude.1.13.7.3Intake air filterAn airfilter is mounted on the carburettor. Operation without air filter isprohibited except for conservation of the engine see engine manualsection 5.Maintenance Manual DG-808CIssued: June 2005 1.221.13.8Fuel injection (primer)The engine is equipped with a fuel injection system for engine start(primer) instead of a choke butterfly valve. The injection valve ispositioned on the engine close to the carburettor.The injection pressure is provided by the electric fuel pump. Via aswitch in the instrument panel the primer can be switched off or toautomatic operation.With automatic operation the control unit controls the amount of fuelinjected in correlation to the coolant temperature.With a cold engine the full amount will be injected and injectioncontinues for a certain time to prevent the cold engine from stopping.With a warmer engine a smaller amount will be injected in pulsesaccording to the temperature. With a hot engine nothing will beinjected. The DEI-NT displays a syringe on the centre display as longas fuel is being injected, setting of the primer see section 4.23.1.13.9Flexible fuel bags in the wings (Option)The fuel bags should normally be kept in the wings.Instructions for replacement see sect. 4.10.If the bags have been removed, they should be stored at temperatures ofca. 15°C - 25°C (59°F - 77°F) and relative humidity of 50-70%.The bags have to be protected against light and should not be storednear electrical machines.When stored the tanks should not be emptied completely but contain atleast 0.5 l (. 13 U.S.gal) of fuel or a thin engine oil (e.g. SAE 10)should be filled into the tanks.Before reinstallation check the bags for any wear or cuts. Be careful notto damage the tanks.Note:Also if the tanks remain in the wings, they should not be emptiedcompletely for longer storage periods.Maintenance Manual DG-808CIssued: June 2005 1.231.14Electrical systemNote:Before doing any work on the electrical system, isolate the powersupply by switching off the main switch. The batteries should also bedisconnected before working in the relay compartment. This is done bydisconnecting the red cable marked with a black ring from the fuseterminal. See the sketch below.In addition the plugs from the wiring leading to control unit or DEI-NTshall be sealed with tape when they are removed from the control unitor from the DEI-NT.1.14.1Layoutsee wiring scheme and wiring plan enclosed to this manual.1.14.2Batteries•The installed battery-pack consist of 4 batteries 6V 10 or 12 Ah withscrewed terminals. The batteries are wired in series and parallel tosupply 12V/20 or 24Ah. The two 12V packs (wired parallel) areprotected by fuses against discharging each other when defective andagainst over current.•The batteries are charged by a generator installed in the engine.•Recharging is via the socket 12 V in the main bulkhead. Thereforeswitch on the main switch. to the first (charging) position. You don'tneed to remove the batteries for charging.•Warning: Use only automatic chargers suitable for sealed liquid acidbatteries. To charge the batteries to their max. capacity such a chargerwith a max. output voltage of 14.4 V is required (most chargers supplyonly 13.8 V). A suitable charger Z 08 is supplied by DG Flugzeugbau.Note:Don't charge longer than for 1 week.disconnect thiscablebatteryfusesinstrumentconsoledirection offlightMaintenance Manual DG-808CIssued: June 2005 1.241.14.3Control unitThis aluminium box is located in the relay compartment. The controlunit incorporates the following functions:1.Master switch relays.2.Control of the extension-retraction procedure. The extensionretraction relays are also mounted inside the unit.3.Regulator/generator, also supplies power to the fuel- and coolantpumps with the masterswitch off.4.Startermotor control: The starter motor is actuated by a powerelectronic, no relays. This applies to the normal engine start(ignition on) and also the slow turning of the propeller intoretraction position (ignition off). Activation is via the starterbutton.5.Control of the primer valve.6.Control of the refuelling pump.7.Fuses for several circuits are installed in the control unit see section1.14.13.Warning:To avoid damage disconnect the power plug first whenremoving the control unit. Plug in the power plug after the other plugswhen installing the unit,Caution: When you plug in the connector plugs, carefully fix the plugswith their screws.1.14.4Generator – Regulator:The generator is located in the ring gear housing and is incorporatedwith the ignition/ timing sensors. It is connected to a voltage regulatorand can provide a maximum charging current of 10 Amp. The regulatoris located in the control unit see sect. 1.14.3. The generator supplieselectrical power to the fuel and water pumps, even with the masterswitch off.1.14.5Master Switch:The aircraft is supplied with a master switch (no separate engine masterswitch). The master switch supplies inonposition electrical power toall systems.The master switch is a key operated switch located in the console belowthe instrument panel. The key switch controls a relay in the control unitwhich cuts off the electric power.Maintenance Manual DG-808CIssued: June 2005 1.251.14.6Engine elapsed - time indicator:The engine time indicator is incorporated in the DEI-NT and counts assoon as the proximity switch detects that the propeller is turning andtherefore counts only the pure engine running time.In addition the time to the next 25 hour maintenance will be displayed.When the maintenance has been executed, this time must be reset tozero in the DEI-NT set up menu.1.14.7Electric pumps:First fuel pump:Power supply from the batteries and from thegenerator (protection via a re-settable fuse in the control unit).Coolant pump:Power supply from the batteries and with the enginerunning directly from the generator (protection via a re-settable fuse inthe control unit).Second fuel pump:Power supply only with the engine running directlyfrom the generator (protection via a re-settable fuse in the control unit)1.14.812 V Socket:The socket is located in the fuselage main-bulkhead (behind the pilotsleft shoulder). It is used for:- battery charging (main switch in charging position)- to provide power for external accessories (main switch “on”).Required plug see sect. 8.2.Connection of the socket terminals: centre pin is positive.1.14.9Power plant extension-retraction mechanism:See also sect. 1.12The automatic extension and retraction is controlled by the control unitsee sect. 1.14.3.The extension-retraction motor will be switched off at the end limits byposition switches see sect. 1.12.5.Caution:If the proximity switch (see sect. 1.14.15) is defective (shortcircuit) a safety interlock in the control unit prevents the engine frombeing retracted automatically with the propeller not in the correctposition. The retraction of the powerplant must be done with themanual switch. The DEI-NT will display the failure message “RPMPickup”. The proximity switch must be exchanged prior to the nextengine start.Maintenance Manual DG-808CIssued: June 2005 1.261.14.10Manual extension-retraction switchManual extension and retraction is via one switch which is located onthe instrument panel. When this switch is operated, the automaticextension/retraction system will be switched off. The automatic systemwill be switched on again when you operate the ignition switch. Themanual switch activates the extension/retraction relays in the controlunit directly, bypassing the safety.1.14.11Starter Press ButtonThe starter press button is located in the centre of the throttle handleand activates via the interlocks the starter relay in the control unit, seesect. 1.14.3.1.14.12WiringThe wire gauges are given in the wiring plan 8E250 at the end of thewire No. inm2 or in AWG.Shielded wires may be identified by circles at their ends.Specification AWG mm2MIL-W_22759/16- 6 -WS 6 13MIL-W_22759/16- 8 -WS 8 8MIL-W_22759/16- 10 -WS 10 6MIL-W_22759/16- 14 -WS 14 2MIL-W_22759/16- 16 -WS 16 1,3MIL-W_22759/16- 18 -WS 18 0,9MIL-W_22759/16- 22 -WS 22 0,4MIL-C_27500- 22 TG1T14 22 0,4 with shieldingMIL-C_27500- 22 TG2T14 2x22 2x0,4 with shieldingRG 174 with shieldingJCJ / IEZ584-3 2x24 2x0,22 NiCrNi withshieldingLiYCY 4x0,25 withshielding94F8128 18 1 high flexiblewires located at the engineInstead of wires from the MIL specifications mentioned above suitablewires approved for aircraft use from other aircraft or MIL specificationsmay be used: Operating range min.: -55°C up to 105°C (-67°F up to220° F), in the engine compartment up to 150°C (300°F), operatingvoltage600 V.Maintenance Manual DG-808CIssued: June 2005 1.271.14.13Circuit breakers and fuses1. In the console of the instrument panel:a) circuit breaker 2 A for electric variometers etc.b) circuit breaker 3 A for the radioc) 3A for turn and bank or artificial horizond) circuit breaker 3 A spare eg. for the transponder2. The battery main fuses are located in the seat shell at the right hand sideof the instrument panel: 2 pieces 60 A.3. Fuse 250V 0.2A 5x20 m for the fire warning light located in the wiringnear the master switch.4. Resettable fuses are installed in the DEI-NT unit for the followingcircuits:Tankoscillator 0,2AAlarm outlet 2 fuses 0,2AChange over switch when extending the powerplant 0,2A e.g. for aHeadset.5. In the control unit:Resettable fuses are protecting the following circuits:a) DEI-NT 0.4Ab) Proximity switch 0.2A,c) Engine extension-retraction motor 10 Ad) full tank sensor 0,05Ae) 12 V socket 4 Af) bug wipers 7Aand a safety fuse for the Generator 15AThe following circuits are protected by their semiconductor switches:a) Fuel pump 1b) Fuel pump 2c) Coolant pumpd) Refuelling pumpe) Propeller brake motor1.14.14Position switches for the powerplantsee sect. 1.12.5 and 1.12.6.Maintenance Manual DG-808CIssued: September 2007 TN800/34 1.281.14.15Proximity switchThe proximity switch at the engine receives the switching pulses by thesteel pins located at the upper drive belt pulley, see drawing 8M110 atthe end of this manual.The proximity switch effects the following functions:1.Activation of the retraction mechanism and indication in the DEINT2.Pulses for the RPM measurement3.Electric propeller-brake (Option)The switch must be adjusted so that the propeller can't hit the enginedoor during retraction. If the switch is moved (distance to the steel pinsreduced) the range will be enlarged.If the distance is too large, the RPM measurement won’t workcorrectly.Check if the switch switches by watching the control light at the rearend of the switch or on the DEI-NT display (main switch on).For a new adjustment start with a distance of 1.8mm (.071 in.).It is absolutely essential to secure the switch with the 4 counter nuts, asdamage to the switch will stop the RPM measurement and theretraction-extension control.With a defective proximity switch (short circuit) the failure message“RPM Pickup”.will be displayed on the DEI-NT.1.14.16Refuelling pump systemsStart the pump by pressing the push button located in the fuselagemain-bulkhead (behind the pilots left shoulder). As soon as the fuselagetank is full a built in device automatically switches off the pump. If youwant to interrupt or to stop the filling procedure before the tank is fullpress the push button again. Starting the pumping again is only possibleby pressing the push button again.The system is controlled in the control unit.1.14.17Connector plugs between fuselage and engineExcept for the starter motor positive and earth wires all wires can bedisconnected by multiple plugs near the hinge of the powerplant (at thebulkhead in the front upper edge of the engine compartment) tofacilitate the removal of the engine.Maintenance Manual DG-808CIssued: September 2007 TN800/34 1.291.14.18DEI NT= (Digital Engine Indicator)For a description of the readouts and the various functions and the setup menu see flight manual sect. 7.4. The DEI-NT controls all functionstogether with the control unit see section 1.14.3.- The RPM measurement is fully digital and counts the impulses ofthe proximity switch.- The coolant temperature (CHT) is measured by a temperature probewhich is screwed into the coolant circuit in the rear cylinderhead.- Fuel level measurement see sect. 1.13.6.FunctionsThe following functions are controlled by the DEI-NT:a) by the ignition switch- the ignition (shorting of the magneto coils)- with the ignition switched off the engine automatic retraction andthe control of the propeller position and propellerbrake will beactivated.- with the ignition switched on the electric fuel pump, coolant pump,the automatic extension of the engine and the control of the startermotor will be activated.b) the RPM indicator controls a relay which prevents the starter motorworking whilst the engine is running.c) the limit switch see sect. 1.12.5 at the engine mount activates thecontrol of the starter motor only when the engine is extendedd) the proximity switch see 1.14.15 prevents the automatic retractionof the engine as long as the propeller is not in the correct positionfor retraction (with the manual extension-retraction switch see sect.1.14.10 not operated).Note:If a new DEI-NT or a replacement DEI-NT should be installed,you have to report your actual elapsed engine time to DG Flugzeugbauto enable them to adjust the new DEI-NT to that value.Warning:with the connector plug disconnected from the DEI-NT, theignition is not short-circuit. This means the ignition is on.Don't turn the propeller!1.15Pitot and static system1.15.1Layoutsee diagram 61.15.2MaintenanceNo special maintenance needed.Maintenance Manual DG-808CIssued: June 2005 2.12Inspections2.1Daily inspectionsee flight manual section 4.32.2Regular inspectionsA After 200 flight hours and during the annual inspectionCheck the rudder cables for wear especially around the S tubes on the rudderpedals. Worn rudder cables should be replaced (see section 4.2.Check the sealing of the rudder (see section 1.3.5.B Annual inspection•Execute all items of the daily inspection see flight manual section 4.3.•Inspect all bolted connections and locking devices ie. locknuts, split pins etc.•Check all metal parts for adequate greasing and rust prevention. (see section3.3).•Check the control surface deflections (see sections 1.2 up 1.4).•Check the free play in all control circuits (see section 1.2up to 1.6)•Check the fore and aft play of the wings (see section 1.10).•Check the canopy emergency releases according to section 7.14 of the flightmanual.•Check the fin ballast tank system according to section 1.8.3•Check the powerplant.•Check the friction brake of the throttle control (see sect. 1.11.8).Check the torque of the propeller bolts see sect. 3.5.1. item 25 of this manual.•Tow hooks:The operating and maintenance instructions for the releasemechanisms, see sect. 0.5 of this maintenance manual have to be followed.•All-up weight and centre of gravity:These should be checked at leastevery 4 years during the annual inspection.Maintenance Manual DG-808CIssued: June 2005 2.2C Every 3 monthsCheck the emergency canopy release according to flight manual sect. 7.12.Only version Classic: Check the tension of the lines of the waterbagattachment (see section 4.1).D Special inspectionsTow hookAfter a wheel up landing, the tow hook mechanism is to be carefullychecked for any damage.After a landing where the fuselage nose has touched the ground, the nosetow hook (Option) is to be cleaned and to be checked for correct functioning.Clean the hole of the PC port (necessary for the stall warning) locatedbehind the fuselage nose on the lower surfaceC.G. weighing:After all work which may influence the C.G.Maintenance Manual DG-808CIssued: June 2005 2.32.3Inspections after a heavy landingThe whole aircraftCheck that the tailplane is still properly aligned in the vertical andhorizontal axis. Check the wing oscillating frequency with respect toprevious checks.WingsCheck the wing pins and bushes for any deformation - are there any whiteareas around the bushes?Root ribsAre there any cracks at the rib/wing skin joint or rib/spar joint? If so,remove any paint or filler to see if the crack continues into the structure.Any white areas around the bushes?Outer skinsCrushing, cracks, delaminations?Note:hairline cracks from the edges of the airbrake housing and on thewing leading edge running along the span are harmless, if these don'tenlarge when you press on the wing shells.FlaperonsCrushing, cracks, delaminations?Hinge mounts checked? - Control circuit drives checked?FuselageFuselage wing connection:White areas, increased free play, bent lift pin tubes, difficult assembly?Torsion check:Hold the fuselage fixed and from the top of the fin try to turn the fin aroundthe fuselage. Does the fuselage show any excessive deformation?Are any cracks made visible while applying this torsion?Maintenance Manual DG-808CIssued: June 2005 2.4Fuselage - fin intersection:Check for cracks.Remove gelcoat and any filler along the cracks. Apply pressure to the fin (pushthe fin towards the nose as well as applying torsion). Do the cracks penetrate theglass fibre structure?Disassemble the rudder and check the glued connection of the fuselage endbulkhead and the fin trailing edge web.To check the elevator control circuit and the bulkhead attachments in the finarea, the tailwheel and the cover plate in the wheel box should be removed.When reassembling glue the cover plate with silicone.Tailplane attachment:Increased free play? Cracks in the fin top rib, fin sparend with tailplaneattachment, especially around the bushes?Rudder mounts:Increased free play? White areas in the glass fibre, bent rudder hinge pinsupports?Fuselage skin:outside: cracks, nicks, folds?inside: white spots, zig zag white lines, cracks?Has any bulkhead become loose?Tow release:Especially after a wheel up landing, check for dirt etc., check for properfunctioning. Has the tow release housing become detached from the fuselage?Front main bulkhead:Cracks? Shoulder strap attachment point?Belly harness attachment points:Check for cracking around the mountings in the seat and excessive free play.Controls:Check for proper functioning and condition of all controls and adjustmentmechanisms (i.e. rudder pedal adjustment, tow release, air brake, control columnand trim etc.).Maintenance Manual DG-808CIssued: June 2005 2.5Instruments:Proper functioning? Dirt in the static ports or in the pitot probe?Engine compartment:Check for damage of the walls. Does the engine retract without scratching theside walls? Do the engine doors fit as well as before?Check the condition of insulation and fire resistant paint.Undercarriage:Check to insure if properly aligned? No bent forks? Proper extension andretraction? Any dirt in the forward fork pivot?Any white areas or cracks in the wheel box? Remove the baggage area floorpanels and inspect the wheel box from above. Undercarriage control circuitcondition. Is there free play between actuating lever and rear upper fork?Tail wheelAny cracks or white patches around the attachment?Is the tail wheel fork bent?In addition:Execute all checks of the daily inspection according to flight manual section 4.3.Maintenance Manual DG-808CIssued: June 2005 2.62.4Inspection procedure for increase of service time1.GeneralThe results of fatigue tests of wingspar sections have demonstrated that theservice time of GFRP/CFRP gliders and motorgliders may be limited to12000 hours, if for each individual glider (in addition to the obligatoryannual inspections) the airworthiness is demonstrated according to a specialmulti-step inspection program particularly with regard to the service life.2.DatesWhen the glider has reached a service time of 3000 hours, an inspection mustbe done in accordance with the inspection program mentioned under point 3.If the results of this inspection are positive or if any defects found have beenduly repaired, the service time of the glider is extended by another 3000hours to a total of 6000 hours (first step).The above inspection program must be repeated when the glider has reacheda service time of 6000 hours. If the results of this inspection are positive or ifany defects found have been duly repaired, the service time of the glider isextended to 9000 hours (second step).When the glider has reached a service time of 9000 h the above inspectionprogram must be repeated. If the results of the inspection are still positive, orif any defects found have been duly repaired, the service time may beextended to a total of 10000 hours (third step).Proceed analogous when reaching 11000 hours (4. step).3. Ask the manufacturer for the necessary inspection document.4. The inspection must only be done by the manufacturer or by a licensedrepair station or inspector.5. The results of the inspections have to be recorded in an inspection test reportwherein comments are required for each inspection instruction. If theinspections are done outside the manufacturer's facilities, a copy of therecords must be sent to the manufacturer for his evaluation and information.Maintenance Manual DG-808CIssued: September 2007 TN800/34 2.72.5Inspection procedure for the controlsCheck of flaperon and airbrake controls at the wing roots:Remove the plastic cap in the rear wing root rib. Insert a mirror withapprox. 30 mm (1.2 in.) diameter in this access hole.Maintenance Manual DG-808CIssued: June 2005 3.13Maintenance3.1General maintenanceSee also flight manual section 8.Exterior surfaces of the fibre reinforced plastic partsThe surfaces are coated by a UP-gelcoat or by PU paint (Option). This gelcoat isprotected by a hard wax coating which has been applied during production witha rotating disc ("Schwabbel" procedure). Do not remove the wax, because thiswould lead to shading, swelling and cracking of the surface. In general, the waxcoat is very resistant. As soon as the wax coat is damaged or worn, a new coathas to be applied. If you store your aircraft often outside, this may be necessaryevery half year! "Schwabbel" procedure:The best method is with an electric power buffer as we do in the factory. Also anelectric drill may be used. Speed approximately 2000 RPM. Two packages ofspecial cloth discs (Schwabbelscheiben) have to be installed. A block of hardwax has to be pressed against the rotating discs. By doing so, the wax becomeshot and is taken up by the cloth. The hard wax and the cloth discs should bepurchased from the DG Flugzeugbau factory.Wax Part-No. 70000121Cloth disc Part-No. 70000600You get the best effect when polishing 90° to the microscratches of the sandingprocess.Note:Make sure that the surface does not get too hot, otherwise the finish willbe damaged. Therefore move the polishing machine all the time, and do not stayon one spot!Maintenance Manual DG-808CIssued: June 2005 3.2Plexiglas canopy:Small scratches on the exterior surfaces of the canopies can be removed by the"Schwabbel" procedure (see above). Lock the canopies to the fuselage!Metal parts:The pins and bushes for rigging the aircraft are not surface protected and mustbe covered with grease all the time (see section 3.3). The other metal parts,especially the control stick and all handles, should be preserved with metalpolishes occasionally.3.2Maintenance of the airframeThe airframe is service free except for the care of the surfaces (see above) andgreasing and oiling of the control system and all pins (see section 3.3).After a landing in a soft field, the undercarriage box and tow hook should bethoroughly cleaned.Maintenance Manual DG-808CIssued: September 2007 TN800/34 3.33.3Greasing and oilingOnce a year your glider should be carefully checked and all bearings, includingcontrol surface hinges, should be cleaned and greased if necessary. The variousgreasing points are as follows:•Flaperon drive connections at the flaperon.•Airbrake drive connection - in airbrake box, also grease the brake paddlepivots.•Remove the access panel on the left hand cockpit wall and grease all thepushrod guides.•Remove the baggage compartment floors and open the baggage compartmentrear cover to grease all bearings.•Remove the control column cover and grease all the bearings associated withthe control column.•Grease the rudder pedal adjustment slide.•Oil all hinge points on the undercarriage in the undercarriage box.•Clean and grease all control surfaces hinges.•Clean and grease the control hook-ups for flaperon, airbrake and elevatorcontrol.•Clean and grease all pins and bushes of the wing and tailplane attachment.•Take off the canopy and clean and grease the locking mechanism. Afterreinstalling the canopy, check the force needed for emergency release withthe red handle, using a spring balance. The force should not exceed 200 N(44 lbs.).•Clean and grease the power plant see sect. 3.5.Note:The greases we recommend are lithium based pressure-resistant anticorrosion greases or lithium-soap greases (multi-purpose greases for rollingelement bearings).Use thin engine oil e.g. SAE 5W30.Note:The sliding guides of the following parts are made from Teflon andshould not be greased:Airbrake control handle 6St9 on 6St15 see diagram 3If these parts have been greased inadvertently you have to disassemble the partsand to clean them completely with Acetone.Maintenance Manual DG-808CIssued: June 2005 3.43.4Damage of the airframeBefore every flight, especially after a longer period of non-use, an inspectionshould be carried out. Check for any small changes such as small holes, bubblesand uneven areas on any skin surfaces, as these signal that something may bewrong. With major damage, contact the DG Flugzeugbau factory immediatelyand send photographs and a damage report from a licensed inspector or from anappropriately rated mechanic. With this information, the correct repairprocedures can then be determined.Minor damage such as small cracks and holes in the skin surfaces can berepaired by a certified repair station.Additional information, such as a listing of all materials used in your aircraft canbe found in the repair manual.Home repairs should not be attempted when:•the main spars or the spar ends are damaged or major fittings on the wings,fuselage or tailplane are broken out or white patches are noted around themin the laminate!•When areas are so badly damaged that component parts cannot be repairedwithout special jigs for proper positioning and alignment!•Whenever it is necessary to cut into undamaged areas to execute repairs!Maintenance Manual DG-808CIssued: September 2007 TN800/34 3.53.5Servicing the EngineCaution: If you don't operate the engine for periods longer than 2 months youmust preserve your engine according to the instructions in the engine manual.The same applies for any overseas transportation.Caution:With an optional BBSA slipping-centrifugal clutch installed to theengine refer to Solo technical note No. 4600-2-2 attached to this manual forservicing the clutch.3.5.125 hour inspectionNote:The engine time until the next maintenance is displayed on the DEI-NToperating time screen. After completion of the 25 hour inspection reset this timeto zero, see section 4.23.The following checks and maintenance work should be done every 25 hoursengine time.Items 1, 2, 3, 7, 8, 10, 13 and 26 should be executed at least 1 year after the last25 hour inspection, preferably with the annual inspection.Checklists for this maintenance work are in the enclosures of this manual. Pleasecomplete the checklist when executing the inspection and file it in the aircraftlog.1. General visual inspection.2. Change spark plugs. Check if the spark plug connectors have a tight fit onthe spark plugs after you have exchanged the spark plugs. If not, theconnector must be replaced.3. Exchange the fuel filter. Use only a transparent filter, type see section 8.1.Assembly see diagram 11c.4. Measure fuel flow (see sect. 1.13.3). Disconnect the hose at the T-junctionbehind the rear carburettor. Hold the hose into a measuring container. Switchon the electric fuel pump with the ignition switch. Determine the time forsupplying 1 litre of fuel. For the measurement a minimum of 10 l of fuelshould be in the fuselage tank. Note down the value, max. time is 90 secondsfor 1 litre.Maintenance Manual DG-808CIssued: June 2005 3.65. Remove the carburettor cover and membrane, remove the needle valve, flushthe carburettor by switching on the fuel pump. The fuel must spout out as apowerful stream. If a large amount of fuel leaks out of the carburettor whenyou remove the membrane this is a sign that:a) a dirt particle prevents the needle valve from closing completely.b) the main nozzle is clogged (dirty), so that the engine can't receive thefull amount of fuel. In this case you have to disassemble the main nozzleand to clean its chamber, see sect. 1.13.7.2 item 2.c) Check the connection of the throttle cable for damage and wear.b)Primera) Check the filter of the primer valve. The filter is installed in the fueldistributor in which the primer valve is inserted. Loosen the hose clampsand the mounting bolt of the distributor and pull out the primer. Flow fuelthrough the filter in reverse direction and check that as the fuel comes outof the filter any dirt is removed. In addition flow fuel in reverse directionthrough that outlet of the multiple-connector where the excess fuel linerestriction is installed. Reinstall the connector.b) Check the function of the primer valve and nozzle (engine must be cold).Switch the primer switch in auto position. Remove the air intake filter.Enter the DEI-NT set up menu and set primer test Y, then switch on theignition and press the starter button. Now the DEI-NT must display asyringe on the centre display and fuel must be injected via the nozzle intothe intake manifold of the carburettor without the starter motor operating.Warning:Test only for 2-3 seconds, otherwise you may flood the engine.Enter the DEI-NT set up menu and set to primer test N, otherwise thestarter motor will not function.c)Check the hose which connects the primer valve to the carburettor for anydamage.d)Leak test of the primer valve: with the ignition on (fuel pump running)fuel must not be injected.Maintenance Manual DG-808CIssued: June 2005 3.77.Check all fuel lines for any wear, kinks, tight fit and leaks. Check especiallythe fuel lines in the engine compartment, switch on the ignition to run thefuel pump.8.Check the intake airfilter of the carburettor for excessive dirt and wear, washwith pure petroleum spirit and blow compressed air in reverse directionthrough the filter. Spray the outside with oil for filters with cotton fabric,reinstall the filter.We recommend exchange of the filter every 25 hours. Also new filters mustbe sprayed with filter oil.9.Check all cables and associated levers and the propellerbrake (see sect.1.11.8 and 1.11.9). Replace levers and pins of the brake in case of excessivefree play. Replace cables when worn.10.Clean engine and radiator11.Check cooling system for leaks, refill coolant if necessary, check antifreeze.Check the radiator and its mounting. To check the water pump, switch on theignition. You should hear a buzz.12.Remove the exhaust manifold.Check the cylinders and pistons via the exhaust ports for seizing marks, forcarbon remains and for sticking piston rings. Press against the piston ringswith a suitable tool. The rings must be movable. Black remains on theoutside of the pistons below the rings indicate sticking or damaged pistonrings, this is not acceptable..Illuminate the combustion chamber and check for combustion deposits. Usea torch and mirror for these checks.If seizing marks are detected the engine must not be used. Excessivecombustion deposits have to be removed.With sticking piston rings the cylinders must be removed. Take out thepiston rings and clean the grooves and the rings or replace the rings. Removealso any combustion deposits inside the pistons.Caution:Necessary repair work including removal of combustion depositsmust be accomplished at a certified repair station rated for such engine work.Maintenance Manual DG-808CIssued: June 2005 3.813.Check the muffler for cracks and ensure mounting is secure. Checkespecially the cable which lifts the muffler during engine extension.Check the retaining cable for the muffler lifting cable incl. the rubber cord.Check the movable part at the front end of the muffler for cracks. Check theexhaust manifold (already removed) for cracks. Reinstall the exhaustmanifold, therefore remove any remains of the gaskets, install new gaskets.Check the function of the gas-spring at the muffler frame. Therefore retractthe engine until the muffler pops downwards. The gas-spring must press themuffler-frame securely to its lower stop. Check the length of the cable whichlifts the muffler. To accomplish this extend the engine and press the mufflerbody in a downward direction at its front end with a force of approx. 5 daN(11 lbs.). If the cable is too long or if the spring in the cable has beenpermanently stretched, the muffler will interfere with the exhaust manifold.Check the spring pressure at the coupling of exhaust manifold to muffler. Toaccomplish this, measure the distance between the brackets for the springcouplings at the muffler pipe and at the movable part of the muffler indisengaged and in operating position.Extend the engine via the manual switch to the fully extended position.In operating position the distance should be approx. 1 mm (0.04 in.) smallerthan when disengaged.If the difference should be less than 0.5 mm (0.02 in.) you have to adjust to1mm using the nut on the eyebolt. By this procedure you will pull themuffler forwards in its frame.Note:With new manifold and/or new movable part the difference should beadjusted to 2 – 3 mm (0.04 – 0.12 in.) to allow breaking in of the parts.14.Check all engine nuts and bolts with a torque wrench (see sect. 1.11.10).15.Check the rubber engine mounts, especially for cracks. Therefore applystrong pressure to the propeller mount in forward, backward and sidewaysdirection.Maintenance Manual DG-808CIssued: June 2005 3.916.Check and grease the starter motor gear shaft (don't grease the starter motorgear) Check starter motor for tight mounting. There should be no excessiveradial free play of the starter motor gear axle. With too much free play thestarter must be exchanged.17.Clean the starter ring gear and check for damage. Check if the starter ringgear was bent forwards by the starter motor. There should be approx. 1mm(.04 in.) clearance between starter ring gear and drive belt.18.Remove the fairings which protect the drive belt. Check the drive belt forwear and tension (see sect. 1.11.5). If the drive belt shows signs of wear or ifthere are cracks/tears at the base of the belt teeth, the drive belt must bereplaced. Check the 6 rollers which guide the drive belt for tight fit to theirmounting brackets and for easy turning. If there is any significant friction intheir bearings, the rollers have to be replaced.19.Clean the spindle drive, function check. Check the connection of the spindledrive to the engine especially for cracks in the fork.20.Option BBSA slipping-centrifugal clutch:Check the propeller stopper forwear and function, check especially the actuating spring.21.Check all the hinges on the engine compartment doors for proper fit and anycracks, tears etc. Check if hinge pins are secured properly.22.Oil all hinge points of the powerplant23.Check the time taken to extend the power plant. If it takes longer thandescribed under sect.1.12.3 the gas strut has to be replaced.24.Check the engine retaining cable for wear and kinks.Check thimble and bolt of the upper cable connection for wear.Check the adjustment of the retaining cable according to sect. 1.12.4. Ifnecessary adjust the cable at the adjustment screw in the rear end of theengine bay.25.Check the main bearings of the upper pulley for any free play.Maintenance Manual DG-808CIssued: June 2005 3.1026.Check the tension of the propeller bolts: remove the lockwire, loosen thepropeller bolts and retorque them with a torque wrench, torque value seesect. 1.11.10.Secure again with lockwire.27.Check the propeller blades for any damage.28.Check all electric cables and connectors. Check the terminals especially ofthe starter positive and earth wire for cracks.Note:The critical spots may be covered by heat shrink tubing.29.Check the whole electrical system wiring, ensure all equipment is secure andall connections are OK. Check proper functioning of all systems andfuses/circuit breakers.Ground test run:Warning:Never run the engine without the wings assembled.30.If needed adjust the idle RPM (see sect. 1.13.7).31.Check the magnetos - at 3000 RPM, drop should not be more than 300RPM.32.Check max. engine RPM - 5800 RPM minimum.33.Check EGT's (only with optional EGT probes) EGT should be adjustedaccording to the instructions see sect. 1.13.7, item 5.34.With engine running at full power press the test button for 10 seconds toswitch off the first fuel pump. The engine must run with the same speed withthe fuel supplied by the second pump.After completion of the 25 hour inspection reset the time until the nextmaintenance to zero in the DEI-NT set up menu, see section 4.23.Maintenance Manual DG-808CIssued: September 2007 TN800/34 3.113.5.2Every 3 yearsExchange the coolant, see sect. 4.16.3.5.3After 50 resp. 100 engine hoursWithout optional BBSA friction/centrifugal clutch: The drive belt hasto be exchanged after 50 engine hours.With optional BBSA friction/centrifugal clutch: The drive belt has to beexchanged after 100 engine hours3.5.4After 400 engine hoursAfter 400 engine hours the power plant must undergo a major overhaul.Apart from the items listed in section 3.5.1., the following items alsoneed to be done:1. Remove the power plant and remove the engine from thepowerplant. Ship the engine to the manufacturer or an aircraftengine maintenance workshop approved by the manufacturer andby the authorities.2. Replace all the nuts and bolts on the engine3.Replace the drive belt4.Replace the bearings of the upper drive belt pulley.3.5.5After 6 years1. replace the gasket of the drainer valve2. replace all coolant hoses and the coolant.3.5.6When required1. If the fuel tank is excessively dirty or when the fuel gauge givesfalse indications, a thorough flushing of the fuel tank is required(see sect. 1.13.6).2. If the engine should run rough between idle and full throttle evenafter all the points in sect. 3.5.1. are OK, then it is possible that themembranes in the carburettors have hardened. They should then bereplaced.3. After sudden power loss at full throttle: Check pistons and cylindersfor seizing marks, see sect. 3.5.1 item 12.4. The fuel hoses have no life time restrictions but must be exchangedon condition.Maintenance Manual DG-808CIssued: June 2005 4.14Detailed instructions for assembly and servicing work4.1Water-ballast system(only Version Classic)see diagram 5Replacement of the water ballast bags:Unscrew the bolt attaching the Perlon line to the root rib and attach an additional6 m (20 ft) long Perlon line dia. 3 mm (.12 in.) to it. Also attach a line to the linewhich is fixed at the front of the root rib.Unscrew the water ballast dump valve cap nut which is near the wing root.Remove the dump valve with attached water ballast bag out of its wing stand bypushing the valve towards the wingtip. Remove the valve and ballast tankthrough the hole in the wing root. Remove the Perlon line and loosen the hoseclamp. Replace the ballast tank and reverse the above procedures to install thenew tank.Only Version DG-808C Competition:With the large wing tank 8F71 (75 l) the check valve at the parting of the tankhas to be taken out and to be installed in the new tank. Clean and test the checkvalve for proper function prior to reinstallation.When you turn the valve so that the spring loaded pin points downwards, the pinmust be moved by the ball of the valve. Check both pins. For installation mountthe check valve on a rod dia. 10 mm, 3 m (10 ft.) long. The side without theturned cut-out for the hose clamp is to be installed inboard.The lines holding the tank are to be fixed so that the key ring will remain 5 cm(2 in.) inside of the wing when the lines are just tensioned. By this method thetension of the lines will be satisfactory even if the lines strain.Every 3 months, you should check that the lines are still tensioned. If not, undothe knot and tie it again to the key ring (see above).The front line should not be tensioned.Each time you unscrew the valve, grease its thread, otherwise you won't be ableto open it again.The seat of the valve ball (see diagram 5) should be greased. Fill the new waterballast tank(s) and check for water-tightness and test the dump time.Maintenance Manual DG-808CIssued: September 2007 TN800/34 4.24.2Replacement of control circuit cablesThe following cable connections are approved:3.2 mm dia. control cable construction 7x19 with Nicopress-sleeves 28-3-MCopper and tool No. 51-M850 or 63-V-XPM or 64-CGMP where the M grooveis to be used. The above applies to the rudder cables and the tow release cable.The cable for the rudder pedal adjustment and the fin tank valve are 1.6 mm dia.control cable construction 7x7 with Nicopress-sleeves 28-1C Copper and the Cgroove for tool 64-CGMP should be used.The same type of cable is used for the control cables of throttle and manualpropeller brake in Bowden outers with 2.6 mm inside diameterAttachment of the Nicopress sleeves should only be done using the respectivetool. All the procedures and checks noted by the tool manufacturers should befollowed.Please refer to aircraft inspection and repair FAA AC 43.13-1 B or later issues.Note:Control cables according to MIL-W-83420 I/A (was MIL-W-1511A) orISO 2020 (was LN 9374) should be used.4.3Adjustment and servicing of the control circuita)In all cases, new self locking nuts LN 9348 should be used.b)Bolts which are not secured with locking nuts have to be secured with Loctite243. Before installing the bolt clean the thread and the inside thread. Applyonly 1 drop of Loctite on the bolt thread. Too much Loctite may causedamage when you try to loosen the bolt again.c)With all adjustment work, it should be ensured that the rod ends are notscrewed out too far from the pushrod - see sketch below for allowable max.distances for the two sizes used.Note:All lock nuts (B) are secured by a spring washer (C) DIN 6798 I. Becareful not to loose that washer!A max.ofxmm inchM 6 36 1.4M 8 60 2.36xACBMaintenance Manual DG-808CIssued: June 2005 4.34.4Removal and installation of the undercarriage (main wheel)4.4.1GeneralWarning:A gas strut is installed inside the landing gear box to compensate themass of the landing gear. The landing gear may retract by itself when unlockedby the force of the gas strut, especially when the glider is not in the normalposition. So when working at the landing gear make sure that inadvertentretraction of the landing gear is prevented.Removal of the gas strut in the landing gear control system:Use a screwclamp to prestress the gas strut sufficiently so that the bolts can be removed.4.4.2Removalsee diagram 15 and 161. Disassemble and remove the wheel axle.2. Remove the wheel brake cable at the brake lever by loosening the attachmentscrew.3. Remove the wheel insuring that the hub locking pin comes free out of the lefthand front fork.4. Rear fork: From inside the undercarriage box remove the three boltsM 6 (SW 10) that secure parts 6FW3 and 8FW42. After removing thebaggage compartment floors disassemble pushrod 8FW47 from bellcrank8FW42. Disassemble the gas strut from bellcrank 8FW42.5. Front fork: After removing the baggage compartment floors, the axle can beunscrewed and the whole thing removed through a 20 mm (.79 in.) dia. holealready drilled through the left hand fuselage side.4.4.3InstallationReverse the above procedures - a new brake cable should be provided - see sect.1.5.2 for brake adjustment procedures.Maintenance Manual DG-808CIssued: June 2005 4.44.4.4Filling and bleeding the hydraulic disc brake(Option)Note:filling and bleeding the system has to be done from the lowest pointwhich is the brake cylinder assembly at the wheel. Otherwise the system can’tbe bled completely.Necessary tools:1.1 open-end wrench 1/4" = 6.35 mm for the bleeder valve at the cylinderassy..2.1 open-end wrench 11/16" = 18 mm.3.1 Plastic syringe acid resistant, volume ca. 100 ml (6 cu.in.). Use thissyringe for brake fluid only!4.1 bleeder assy. Tost No. 075890.5.1 m (3 ft.) transparent PVC hose inside diameter 3 mm (0.12 in.), fixed tosyringe and bleeder assy. with hose clamps.6.Instead of items 3 –5 we recommend to use the Tost No. 059010 filler assy.For hydraulic disc breaks including 075890 bleeder.7.Brake-fluid DOT 3, DOT 4 or SAEJ 1703.1.Preparations- raise the fuselage, extend the landing gear- fix left wheel door in the fully open position- set the airbrake control in the retracted position- remove the baggage compartment floor and rear cover. Remove the reservoirmounting plate. Check that the actuating cable for the master cylinder isloose and if the piston rod of the master cylinder is at its stop.- Remove the mounting bolts of the main brake cylinder. Lift the cylinder sofar that the cylinder comes to a higher position than the highest point of thebrake hose. Hold the cylinder in this position for filling.2.Filling- remove the cover of the reservoir including the gasket.- fill the syringe with brake fluid, therefore screw off the black part of thebleeder assy., eliminate all air bubbles, reassemble the black part.- remove the protection cap from the bleeder valve, attach the bleeder assy.and fix it with the wrench 11/16".- open the bleeder valve at the cylinder assy., use the 1/4" wrench, fill inslowly the complete volume avoiding air bubbles.- fill the complete system up to 15 mm (0.6 in.) above the lower edge of thereservoir.Maintenance Manual DG-808CIssued: June 2005 4.5-lower the cylinder to it’s initial position. Rotate the cylinder so far, that therear end of the cylinder comes lower than the front end. Continue filling thesystem with the cylinder in this position.- fill the complete system up to 15 mm (0.6 in.) below the upper edge of thereservoir.-avoid over filling-first close the bleeder valve at the cylinder assy., then close the reservoir(cap and gasket) and remove the bleeder assy..-close the bleeder valve with the protection cap.-Fix the cylinder and the reservoir again in their correct positions.Warning:Brake fluid is poisonous!Protect your hands and clothes. Remove all spilled brake fluid. Clean all partswhich had contact with brake fluid with alcohol, don't use fuel or solvents.3.Check brake pressure:- extend the airbrakes, there must be a strong pressure when the wheel brakeengages.- check several times, the wheel brake must engage at the same point everytime- if this is not the case, you have to bleed the system again4.Check the hydraulic brake system for leaks:- extend the airbrakes with high force and hold it in this position for 2minutes.Then check the whole hydraulic system visually for leaks. If necessarytighten the screwed joints or replace the sealings and bleed the system again.Note:The adjustment of the length of the cable between the master cylinder andthe airbrake control shaft restricts the max. airbrake extension height. Theadjustment of this cable should be done with the glider rigged.5.Bleeding the hydraulic brake system- Remove the brake fluid from the reservoir using the syringe.- Then execute again items 2 and 3 of this instruction.Maintenance Manual DG-808CIssued: June 2005 4.64.5Fixing excessive free play of the canopyShrinking of the fibre reinforced plastic material may result in free play betweenthe canopy hinge 8R48 and the canopy.You can fix the free play as follows:a) Take off the canopy and remove the emergency release spring.b) Tape the hinge completely and coat it with demoulding agent.c) Roughen the depression for the hinge at the canopy carefully withabrasive paper.d) Fix a piece of wood 10 by 10 mm (3/8 in.), 2 mm (1/12 in.) thick withdouble-sided tape at the rear end of the hinge (see sketch).Put on the canopy and try to lock the canopy to the hinge. If this is notpossible remove a small amount of the wood thickness.If there is still free play, use a thicker piece of wood.e) Mix epoxy resin with cottonflocks and apply it in the depression see c).f) Reinstall, close and lock the canopy.g) After the resin has cured, take off the canopy again.h) Trim the depression, remove the tape and reinstall the canopy.i) Finally check the canopy emergency release according to flight manualsect. 7.12. The opening force for the emergency release should in no caseexceed 20 daN (44 lbs.)!wood8R48Maintenance Manual DG-808CIssued: June 2005 4.74.6Removal and installation of the flaperons4.6.1Removal of the flaperons1.To remove the flaperons with unparted wings or to remove the flaperonsfrom the 18 m wingtips you have to remove the tip parts (approx. 20 mmwide) from the flaperons.Therefore you have to remove the white tape and the screw (Allen key tool2.5 mm, 0.1 in.). Pull off the tip part to the rear.Now, you can slide the flaperon towards the wingtip for removal.2.Carefully break away the fairings from the control surface horns at theflaperons. Then screw away the horns (Allen key wrench 4 mm, 0.16 in.)3.Remove the selflocking nut and the washer at the inboard flaperon hinge(Allen key wrench 8 mm, 0.32 in.) move the flaperon from the wing bysliding in outboard sense.4.Remove the internal sealing see section 4.7.3.4.6.2Reinstallation of the flaperons1. Reinstall the flaperons. Use new self locking nuts (M5 DIN 985-8 zn).Screw the drives to the flaperons again. Secure the bolts with a drop ofLoctite 243.2. Glue the fairings again to the control surface horns with polyester resin.Apply pressure when gluing to prevent the fairings interfering.3.Push on the tip part to the flaperon, secure with screw and white tape (e.g.Tesafilm).4.Reinstall the internal sealing see section 4.7.3.Maintenance Manual DG-808CIssued: September 2007 TN800/34 4.84.7Control surface seals and turbulatorsNote:To minimise the friction of the seals, the trailing edge of the seals shouldbe chamfered. Apply a fine grinding paper (e.g. 400 grit) between sealing andcontrol surface and move it up and down in spanwise direction to sand thetrailing edge of the sealing.Warning:Use only original materials see section 8. Otherwise the function ofthe sealings is not guaranteed. Sealings which are too loose may cause controlsurface flutter.4.7.1Wing upper surfaceThe sealing is installed in a groove at the trailing edge of the wing.Curved Mylar seal is glued into the groove with film tape at the leading edge ofthe sealing. PVC tape is glued over the sealing to cover the gap between wingand sealing. The leading edge of the PVC tape shall be 5 mm (1/5 in.) in front ofthis gap.4.7.2Wing lower surface turbulatorsa) Version with combi tape:Sealing and turbulator are combined (combi sealing). The combi sealing isalready equipped with selfadhesive film tape. Prior to removing the oldcombi sealing mark the position of the turbulator leading edge with a pencil onthe wing surface, otherwise see sketch distances a. The inboard combi sealing is7.0 m (22.97 ft.) long and 43 mm (1.7 in.) wide. The outboard part is 1.45 m(4.76 ft.) long and 38 mm (1.5 in.) wide.b) Version with dimple tape:Instead of combi tape a dimple tape may be installed as turbulator. The sealingof the flaperon gap is done with the internal sealing according to sect. 4.9.1.Operation without this sealing is not permitted. The leading edge of the tape islocated at distances b in front of the flaperon trailing edge.y measured from fuselage centre line 1 in.=25.4 mm. . . . .hingelinetrailingedgeaPosition ymmammbmmflaperon root 380 155 158contour brake 4500 130 133parting 7250 95 98flaperon tip 8650 78 81bMaintenance Manual DG-808CIssued: June 2005 4.94.7.3FlaperonsTo reduce the friction as far as possible a 38 mm (1.7 in.) wide selfadhesiveTeflon coated glass fabric is glued on the upper side of the flaperon see sketch.Prior to removing the old fabric, mark itstrailing edge with pencil on the flaperonsurface. The fabric must be installed sothat the sealing slides always on thefabric. Cutting the front of the fabric iseasiest if the sealings are not installed.Insert the flaperon and use fulldisplacement.Cut the front end of the fabric with asharp knife along the wing trailing edgesee sketchWith the sealing installed, you have to measure the position of the front end. Cutit off by hand with the flaperon removed from the wing..Internal sealing of the lower wing surfaceWarning:Operation of the glider without this sealing is prohibited.The flaperons are sealed at the lower surface with 38 mm Teflon-glass-fabrictape.a) Removing the flaperons:To remove the flaperons you have to remove the internal sealing first. Peel offcarefully so that the tape does not tear and no remains of the glue remain on thewing surface.b) Reinstalling the flaperons:Remove carefully any remains of the glue. Be careful not to bend the combisealing too far up, so that it won’t be bent permanently and that it doesn’t comeloose.Install the flaperon in the wing but don’t screw on the control surface horn.Rotate the wing upper surface up and deflect the flaperon to its max. negativedisplacement. Use a small brush and apply talcum powder onto the flaperonleading edge. Then deflect the flaperon to its max. positive displacement andremove the talcum powder from wing and flaperon surface.. Clean the gluingareas with Acetone.Deflect the flaperon to its max. negative displacement again and fix in thisposition e.g. with tape.Place the Teflon-glassfabric tape without removing its cover into the slotbetween lower wing surface and combi sealing up to the glue film of the combitape.Version with dimple tape: glue the Teflon glass fabric tape to the wing with10mm overlap.cut off herefulldisplacementTeflon tapeMaintenance Manual DG-808CIssued: June 2005 4.10Press the Teflon-glass fabric tape with a wooden stick into the gap betweenaileron and wing and press the fabric tape to the aileron surface.Then deflect the aileron several times in both directions.If there is still a noise which sounds like the fabric sticking to the aileron andgetting loose again, you should blow compressed air into the fairings of thecontrol linkage pushrod to distribute the talcum powder.Glue a PVC tape (19mm wide) over the leading edge of the sealing.Screw on the control surface horn, securing the bolts with Loctite 243.Glue the fairing again to the control surface horn with polyester resin. Applypressure when gluing to prevent the fairings interfering.Sealings shown for version with dimple tapeMaintenance Manual DG-808CIssued: September 2007 TN800/34 4.114.7.4Horizontal tailplanea) turbulator60° zig-zag turbulators are installed on upper and lower surface.Prior to removing the turbulators mark the position of the turbulator leadingedge with a pencil on the stabilizer surface, otherwisey measured from fuselage centre line 1 in.=25.4 mma = up to leading edgeb) Sealing: As sealing 30 mm (1.2 in.) wide Mylar seals with scarfed leadingedge are used, so that no step occurs.Note: Don’t glue the film tape to theleading edge of the seal.The scarfed leading edge of theseals must be pressed to thestabilizer surface by a PVC tape.Prior to removing the sealing markthe leading edgewith a pencil to the stabilizersurface.4.7.5Vertical tailplanea) Sealing analogous to the horizontaltailplane with Combitape 43/19/06,1.1 m long. The upper end of the tapeshould match the top of the fin.b) Internal sealingAdditional internal sealing with V-sealing strips.Install the V strips according to the sketch.Position Ymma=bmmcmmcentre 072275267,5137,5134turbulator tip 1160 155 77,5ahingelinecPVC tape10 mmfilm tapetrailingedgeb21 mmfin trailingedge5 mmMaintenance Manual DG-808CIssued: June 2005 4.124.8Determination of the moments of the flaperonsDue to the flexibility of the flaperons and the large number of hinges it is verydifficult to determine correct values for the moments. For the measurement youneed a long flat working bench or a similar device. You must produce holdersaccording to drawing 8V 96 (enclosed in this manual). One with 6.5 mm (1/4in.) diameter hole and 4 (or 5 for flaperons without parting) with 5.5 mm (0.22in.) diameter hole. Fit the holders to the flaperon hinge pins. Part 1 (6.5 mm dia)to hinge 1 (at root). Other parts to hinges 4, 7, 10, 13 and 17 in case of flaperonwithout parting.Clamp the holders to the working bench with screw clamps. Remove theflaperon and adjust all hinge points to be in line. A max. tolerance of +0.5 mm(0.02 in.) in up and down and fore and aft direction is allowed.Fix the holders to the bench when in line. Install the flaperon again and measurethe load at the trailing edge at the root 122 mm (4.8 in.) behind hinge axis, seesketch.Start measurement at a 5 degree down position and lift the flaperon slowly to a5° up position. Read spring balance. Lower the flaperon slowly to the 5° downposition. Read spring balance. The load will be lower. Use the average of bothvalues for the flaperon moment. Execute this measurement min. 3 times to besure that no measuring error occurs.The difference between up and down value should be no more than 80 g (0.036lbs.). Otherwise the friction is too high and must be reduced first to obtain areliable measurement.part 2 part 2 part 2part 1122loop of tapeSpring scale should have a max.reading of 1 kg (10 N) or 2 lbs. 1graduation should be 20 g (0.2N) or 0.04 lbs.8V96spring scale14710Maintenance Manual DG-808CIssued: June 2005 4.134.9Working instructions for heat-shrink tubingTo insulate various parts of the electrical system heat-shrink tubing is used. Forrepair and maintenance the heat-shrink tubing often has to be removed. Forremoval use a sharp knife. To insulate again slip a new piece of heat-shrinktubing over the part which is to be insulated.Use a hot air gun (min. 200°C, 390°F) to heat the tubing until it shrinks andgives a tight fit.4.10Securing with LoctiteAll bolts on the engine except for the propeller mounting bolts (lockwire) whichare not secured with locking nuts have to be secured with Loctite 243 (Loctite72 b (672) may be used as an alternative).If a bolt can't be unscrewed you must heat this section with a hot air gun toreduce the locking force of the Loctite.Before reinstallation you have to clean the thread of the bolt and the insidethread from any remains of Loctite. For this procedure use Loctite 18896.If necessary recut the inside thread. Before you apply the Loctite bolt and insidethread have to be degreased with spray cleaner Loctite 7063.Wipe off the bolt and clean the inside thread with compressed air. Repeat twotimes for inside threads.Apply only a small amount of Loctite on the thread. Too much Loctite maycause damage when you try to loosen the bolt again.With blind holes the Loctite must be applied to the thread in the hole and not tothe bolt.All locked and secured bolts have to be marked with red securing paint whichalso marks the respective component at that particular point.Remove the old red securing paint before reinstallation of the bolt.Caution: Loctite must be used within 2 years of production date. Theproduction date is printed on the bottom of the bottle. 96A means January 1996,96B means February 1996 and so on.Maintenance Manual DG-808CIssued: June 2005 4.144.11Replacement of wing fuel tanks (Option)Disconnect the plastic fuel line inside the wing at the quick connector attachedto the wing root rib. Loosen the red black marked perlon cords at theirattachment at the root rib. Attach an extension line 3 mm diameter (1/8 in.) 5 mlong to the red perlon line. Remove the fuel tank by pulling on the perlon cordmarked red and black on the fuel line. Disconnect the wire for the electrostaticconnection.Installation: Follow the removal procedure in reverse. Fill the tank and check forleaks.Tanks type Uniroyal part NO. 4F28:Note:The tanks have no ventilation linesMaintenance Manual DG-808CIssued: June 2005 4.154.12Mounting and tensioning of the drive beltplease refer to drawing 8M110 (enclosed in MM)a)Tensioning of the drive belt1. Tensioning and loosening of the drive belt is accomplished byturning the eccentric axis 8M115, which carries the upper drive beltpulley, against the propeller mount (carbonfibre tower).2. Remove the engine retaining cable from fork 8M119.Caution:Let cable retract slowly, otherwise the retraction bungeemay jump from its pulley located inside the rear end of the fuselage.3. Mark the actual position of axis 8M115 by marking the position offork 8M119 at the propeller mount.Caution:Turn the pulley into such a position that there is no riskthat the actuators touch and damage the proximity switch whenloosening the pulley.4. Remove the 6 mounting bolts which fix the flange of axis 8M115 tothe propeller mount (5 x bolt with hexagonal head, 1 x countersunkscrew).5.Turn the assembly applying a 22 mm open end spanner at the fork8M119 until the next mounting hole in the flange of axis 8M115appears. Therefore press the pulley in upward direction at its frontend. Rotation in clockwise direction increases the belt tension (viewfrom the back, in flight direction).6.Continue with f).b)Indication for drive belt tensionIf the belt with axis 8M115 screwed into place is not quite tensioned,the flange of the axis must be rotated up to the next but one mountinghole (see a) 5.) to tension the belt.After assembling of the flange measure the drive belt tension accordingto section g) and adjust if necessary.c)Exchanging the drive beltIn addition to a):1. Remove the propeller2. Remove the front retaining rings of upper and lower drive beltpulleys.3. Remove the carbonfibre fairings (drive belt covers) from thepropeller mount.4. Disassemble gas-strut and spindle drive from the propeller mount.Caution:Regard the instructions in sect. 4.13.Maintenance Manual DG-808CIssued: June 2005 4.165. When reassembling mount the axis 8M115 2 mounting holes priorto the marked position. Fix the axis with min. 2 mounting bolts.6. Check and if necessary correct the drive belt tensioning see b).d)Initial setting of eccentric axis 8M115If the marking was lost or if a new axis is to be installed, the eccentricmust be positioned as follows:Remove the sealing cap 8M118/1.The groove in the front end of the axis shall point downwards. This isthe lowest position of the eccentric. From this position rotate the axis ina clockwise direction (see a) 5.) from 1 mounting hole to thenext and fix the axis min. 2 bolts in each position to check the drive belttensioning. Proceed until the correct tensioning is reached.During this the axis should not be rotated more than 180° (groove inupper position). However it should be impossible to reach thisposition.e)Reassembly1. Reassembly is the reverse of disassembly. Use Loctite 243 to secureall screws and bolts except for the propeller mounting bolts.Caution: When reassembling the drive belt covers be careful to usethe correct screws. Screws which are too long will damage the belt!2.If the position of the axis has been changed the fork 8M119 must bebrought to vertical position again. Screw out the fork (axis alreadyassembled with all 6 bolts). Loosen the distance washer 23 x 32 x 1from the axis 8M115. Apply a suitable 2 component metal adhesive(e.g. UHU Plus 300) between 8M115 and the washer. Screw in thefork 8M119 again using Loctite 243 for securing until the fork is invertical position. The glue should be pressed together to less than 1mm thickness. Let the glue cure before operating the engine.3.Adjust and secure the proximity switch according to sect. 1.14.15.f)Changing the relation of propeller to enginesee sect. 1.11.41. Execute work according to a), b) and c) items 1,2 and 3.2. Mark upper drive belt pulley and drive belt with a felt pen or withtape.3. Move drive belt forward as far as possible on both pulleys. Then liftthe belt off the upper pulley and rotate the pulley against the drivebelt.Maintenance Manual DG-808CIssued: June 2005 4.17g)Measuring the drive belt tension and tolerancesplease refer to drawing W57 (enclosed in MM)1.Remove the left (in sense of flight) drive belt cover.2.Insert the measuring tool W57 from the right hand side (inside)through the second threaded hole of the drive belt cover (countedfrom the upper end). Lay the Perlon cord around the left hand side ofthe propeller mount and fix it to the other side of W57.Hang a min. 100N (10kg, 22lbs.) spring balance into the cord.Measure the distance between the drive belt surface and the outerside of the propellermount at the same station from the left hand sidethrough the opposite thread with the probe of a vernier caliper. Firstmeasure with no load on W57 and then with 100N (10kg, 22lbs.).3.The difference should be min. 6 mm (0.236 in.) and should notexceed 11 mm (0.433 in.). If the difference is smaller than 6 mm thetension is too high and the load on the crankshaft is excessive. If thetension is too low the drive belt may slip and the relation propeller toengine will change.Option BBSA Slipping/centrifugal clutch:The drive belt tensionshall be lower: 8-12mm.Caution:After installation of a new drive belt check the belt tension again afterapprox. 30 minutes engine time, readjust if necessary.Maintenance Manual DG-808CIssued: June 2005 4.184.13Replacing the bearings of the upper drive belt pulleysee drawing 8M110 (enclosed to this manual)a)Removing the bearings1. Remove the propeller.2. Remove the proximity switch. Its best to remove the switch togetherwith its mounting plate 8M138. Mark the position prior to removal.3. Remove the drive belt see sect. 4.11.4. Remove the sealing cap 8M118/1.5. Bend up the securing washer 20 DIN 462.6. Screw off the nuts KM4 one after the other.Note: left hand thread.Use one of the 2 specially bent hook spanners according to drawingW51 (encl. with this manual). Remove the antirotation securing washer.7. Now you can pull off the complete pulley 8M111 from the shaft8M115.8 Take the inner ring and the rollers of the front bearing out of the pulley.9. To remove the outer rings of both bearings from the pulley you have toproduce 2 pieces of round material each 100 mm (4 in.) long and with47 mm (1.85 in.) and with 53 mm (2.09 in.) diameter.10.Press out the outer rings together with the Nilos rings carefully using apress or a hammer.11.Pull off the inner ring of the rear bearing together with part 8M117/1from shaft 8M115. Use a suitable puller assy..b)Installation of the new bearings1.To press the outer rings of both bearings into the pulley you have toproduce 2 pieces of round material each 30 mm (1.6 in.) long and with51 mm (2 in.) and with 57 mm (2.24 in.) diameter.2. Press in new outer ring together with new Nilos rings.3. To press the inner ring of the rear bearing to the shaft you have toproduce a piece of tube with 32 mm (1.26 in.) inside diameter and 90mm (3.54 in.) long.4. Press the inner ring together with part 8M117/1 to the shaft.5. Fill the space for both bearings with grease.6. Apply grease to the inner ring of the bearing and place the rollers ontothe ring. Apply enough grease to completely fill thebearing.Maintenance Manual DG-808CIssued: June 2005 4.197. Place the pulley onto the shaft with care. It ́s best if the powerplantis retracted so that the shaft is in vertical direction.8. Put the rollers and the inner ring of the front bearing into place. Puton the antirotation securing washer and the first one of the KM4 nuts.Tighten the nut with the other hook spanner see a) 6. until the pulleystarts to rotate a little stiffer than with a loose nut. Put on anew securing washer 20 DIN 462. Screw on the second nut. Securethis nut with Loctite 72B. Fix the first nut with a hook spanner so thatthe adjustment doesn’t change and tighten the second nut as far aspossible. Check again the rotation of the pulley. No free play isallowable.9. Press the sheet metal securing washer into the grooves of the rear nut.10. Fill the sealing cap with grease and put it into place.11. Install the drive belt and adjust it according to sect. 4.11.12. Reinstall the proximity switch and check its adjustment, see also sect.4.11.13. Reinstall the propeller and secure with lockwire according to sect. 4.18.Necessary material1. roller bearing 32205B2. " 320/32X3. Nilos ring 32205 JV4. " " 320/32 JV5. securing washer 20 DIN 4626. grease for bearings SKF LGMT3Caution:Don’t use another type of greaseMaintenance Manual DG-808CIssued: June 2005 4.204.14Removal and installation of the tension gas-strut(engine extension mechanism)a)Removal:1. Take a piece of tube with 12mm (.47 in.) inside diameter and 80 mm(3.15 in.) length and cut it to receive two halfshells.2. Retract the powerplant until the gas-strut is extended a little further than80mm.3. Place both halfshells onto the piston rod of the gas-strut. Extend theengine a little further, so that the two halfshells block the gas-strut.4. Remove the gas-strut.b)Installationis the reverse of removalc) Installation of a new gas-strut1. Extend the new gas-strut with a pulley block to place the halfshellsor2. Install the gas-strut to the front mounting point in the aircraft andproduce a metal plate with two holes diameter 8 mm (.32 in.) 80 mm(3.15 in.) apart. Bolt this plate to gas-strut and propellermount andretract the engine to extend the gas-strut far enough to place thehalfshells. Remove the plate.d)Securing the rod end to the piston rodThe rod end of the gas-strut must be glued onto the thread of the piston rodwith Loctite 638. The correct securing is marked by a red dot of markingpaint on piston rod and rod end. After removal of the gas-strut check if themarking is existing and not damaged. If not the rod end must be screwedoff and glued on again.The same applies with installation of a new gas-strut.Remove any remains of Loctite and any dirt according to the instructions insection 4.8. To tighten the screwed connection, hold the piston rod againstrotation using a small pipe wrench, wrap a piece of fine emery cloth aroundthe end of the piston rod to protect the rod.In addition the rod end is secured with a roll pin 2.5x14 DIN 7346 St, seesketch.Maintenance Manual DG-808CIssued: June 2005 4.214.15Replacement of the engine retaining cablePlease refer to diagram 14 and in addition to diagram 14a1. Extend the powerplant.2. Remove the access panel from the rear engine bay floor.3. Remove the engine retaining cable from the propeller mount. Let the cableretract slowly, otherwise the retraction bungee may jump from its pulleylocated inside the rear end of the fuselage. The bungee pulley is accessiblevia the access hole inside the tailwheel box.4. Pull out the bungee via the access hole in the rear engine bay floor untilyou reach the terminal of the retaining cable.5. Fix the bungee to the floor to prevent it from disappearing into the fuselageboom.6. Cut off the retaining cable and pull it out. Don’t damage the bungee! Don’tloose the steel washer.7. Attach the new cable with thimble and 2 Nicopress sleeves to the bungee.Press the Nicopress sleeve, the end of the cable must be inside the secondNicopress sleeve. Install the steel washer on the cable and wrap Tesaband651 twice around washer and Nicopress sleeves.8. Push the retaining cable via the adjustment screw through the rear enginebay bulkhead and pull it forwards.An absorber element is installed on the adjustment screw. Check if thewasher at the rear end of the absorber is in place and fixed and if theabsorber element is still glued firmly to the adjustment screw, see diagram14a.9. Let the bungee retract slowly into the aft fuselage10. Install the retaining cable together with thimble and Nicopress sleeve to thepropeller mount. Don’t press the sleeve. Adjust theposition of the powerplant according to section 1.12.4. Tighten the cableand press the Nicopress sleeve. Cut off the excess cable.11. Check again the length of the retaining cable. See section 1.12.4.Adjustment is possible at the adjustment screw at the rear bulkhead.12. Reinstall the access cover to the rear engine bay floor.Material:Steel cable diameter 3.2 mm (1/8 in.) appr. 2.3 m (91 in.) long, type see section4.2.2 thimbles 3mm DIN 6899A2 Nicopress sleeves 28-3-MTesaband 651 (selfadhesive textile tape)Maintenance Manual DG-808CIssued: June 2005 4.224.16Filling and bleeding the cooling systemPlease refer to diagram 9Coolant:1 part glycol and 1 part distilled water (up to appr. -40°C,-40°F), you will need appr. 1.8 liter , 0.475 US.gal..4.16.1Inspection of the coolant pump1.Extend the engine2.Remove the coolant hose from the radiator (upper end). Insert the testadapter W59 (drawing see enclosure to this MM) into the hose andsecure with a hose clamp. Install a PVC hose (instrument line) on theother end of the adapter and put its end in a calibrated container.3.Switch on the ignition and measure the time needed to fill 0.2 liters intothe container, then switch off the ignition immediately. Otherwise thepump will suck in air and bleeding may be difficult.Normal time is between 15 and 20 seconds.4.If the time needed exceeds 25 seconds the pump is worn and should beexchanged. Repeat the test after installation of the new pump.5.Remove the adapter and connect the coolant hose to the radiator again.6.Remove the screw cap of the radiator. Press down on cap for easierhandling.and fill in the coolant from the test, if necessary refill coolant.7.Switch on the ignition to run the coolant pump. Run for approx. 1minute. Switch off the ignition. If necessary top up the radiator.8.Close the radiator cap.4.16.2Removal of the coolanta)Prior to removal of the coolant check the coolant pump see above,b)Retract the engine until the engine doors just stay open.c)Remove the straight hose connector GS 16 from the coolant hose on topof the coolant pump and replace it by a T-connector TS 16 (suppliedwith the glider service set).d)Install a hose with 16 mm (0.6 in.) inside diameter to the T-connector.Hold the hose into a container placed below the lowest point of thecooling system.e)Extend the engine. After all liquid has run out of the system, switch onthe ignition to run the coolant pump for a short time.f)Replace the T-connector by the straight connector again.Maintenance Manual DG-808CIssued: June 2005 4.234.16.3Filling and bleedinga)The engine must be cold. Extend the powerplant.b)Remove the screw cap of the radiator. Press down on cap for easierhandling. Fill in coolant until the radiator is completely filled.c)Switch on the ignition to run the coolant pump. Look into the radiator,you must see the coolant bubbling. If this is not the case there may bean air bubble next to the coolant pump in the upper coolant hose.Squeeze this hose several time until the coolant starts bubbling. Run thecoolant pump for approx. 1 minute. Switch off the ignition. If necessarytop up the radiator.d)Close the radiator cap.e)Run the engine to warm up, then run approx. 1⁄2 minute at full throttle.Stop the engine.f)Allow the engine to cool down. Remove the radiator cap and check thecoolant level. The coolant level should be approx. 2 cm (0.8 in.) belowthe top of the radiator. If necessary top up to this level.g)Close the radiator cap again.Maintenance Manual DG-808CIssued: June 2005 4.244.17Installation and removal of the powerplantsee diagram 84.17.1Removal of the powerplantGeneral notes:−Remove all Ty-raps (cable fasteners) which may hinder engine removal.−If necessary heat carefully all bolts secured with Loctite with a hot-air gun toenable easy removal.−Study the notes for engine conservation (see engine manual) prior toremoval of the engine.−To lift out the powerplant from the engine compartment you need a stronghelper or a crane.Necessary toolsSocket wrenches: 6, 8, 10, 13, 14, 17, 19 mmOpen end spanners: 8, 10, 13, 14, 17, 19 mmAllen key wrench: 6 mm1 wire cutter1 hot-air gun1 small screwdriver1 roll insulating tape1 sharp knife2 pliersMaintenance Manual DG-808CIssued: June 2005 4.25I) Fully extend the powerplant(via manual extension switch)1.Remove the lockwire from the propeller fixing screws and remove thesix screws with a 13mm socket wrench. Then pull off the propeller.2.Removal of the engine bay doors, s. section 4.17.3.Unscrew the cable which lifts the muffler when the engine istravelling with a 10mm open end spanner.4.Disassemble the fuel lines by removing the hose clamp from thestarter motor with an 8 mm socket wrench. Then loosen the hoseclamp at the hose connector TS6 with a 6 mm socket wrench. Pull offthe fuel line from the connector and plug the line with a 6mm bolt.5.Separate the throttle cable from the carburettor.6.Loosen both screw clamps of the Bowden wires for the propellerbrake at the brake lever on the engine rear side using a smallscrewdriver and an 8 mm open end spanner.7.Remove hose clamp which fixes the electric wiring of the starter at theengine block. Remove the pole insulating cap from the positiveterminal, then remove the electric wiring from the starter motor with a10mm open end spanner (wire with red marking). Insulate the wireterminals with tape. Then remove the earth wire (wire with bluemarking) from the starter motor.8.Unscrew the powerplant’s retaining cable from the propeller mountwith a 13mm socket wrench and a 13mm open end spanner. Let theprestressed cable retract slowly into the fuselage, otherwise theretaining rubber cord might jump off from the pulley in the fuselage.9.Disconnect the two electrical connections of the waterpump. Removethe waterpump from the firewall by opening the two hose clampswhich fix the pump with a 6 mm socket wrench (To open the upperhose clamp it helps to retract the engine a little). Pull the pump out ofthe hose clamps in an upward direction. If necessary remove furtherTy-raps.Maintenance Manual DG-808CIssued: June 2005 4.26II) Retract powerplant almost completely10.Disconnect the electrical connections at the firewall:a)Disconnect the multiple plug of the wiring set (from serial no. 8-103 on installed in the firewall behind a cover plate).b)Only with EGT-option: Screw off the two screw-in-plugs for theEGT probes .c)Now arrange all wires in a way to enable easy removal of thepowerplant from the engine bay. For this purpose it might benecessary to remove some further Ty-raps.11.Separation of the extension/retraction unit from the propeller mount:a)Spindle drive: Retract powerplant until the propeller mount isapprox. in horizontal position. Unscrew the bolt which fixes thefork to the spindle drive. Then lift the powerplant a little by handto pull out the bolt and let down the powerplant into the enginebay.b)Disconnection of gas-strut from the powerplant s. section 4.13.12.Bend up the securing washers at the two bolts at the hinge axis of thepropeller mount. Unscrew the bolts with a 19mm socket wrench, liftthe powerplant to minimize the load on the bolts and remove themincluding the brass bushes. Finally lift the powerplant out of thefuselage with two persons.Maintenance Manual DG-808CIssued: June 2005 4.274.17.2Removal of the engine from the propeller mountGeneral notes:Before removing the engine from the propeller mount screw four long bolts M10 resp. M12 into the 4 threads at the lower end of the engine block. Thisfacilitates handling on the workbench because the powerplant can be placed onthe screws.Necessary toolsSocket wrenches: 6, 7, 17, 19 mmOpen end spanner 30 mmWrench for spark plugs 21 mm (13/16 in.)Allen key wrenches: 3, 4, 5, 6 mm1 wire cutter1 hot-air gun1 small screwdriver1 flange bolt (incl. in SOLO tool kit)1 puller assembly W40 (drawing encl. to this manual) with1 bolt M 12 x 90 DIN 933-8.8 and4 bolts M5 x 20 DIN 912-10.91 sharp knife1 roll insulating tape1 bucket1. Remove the drive belt fairings from the propeller mount by unscrewingthe 16 bolts with a 3 mm Allen key wrench.2.Remove the drive belt according to section 4.11a) and c).3.Pull off the lower drive belt pulley including starter ring gear from thecrankshaft:a)Remove the front retaining ring from the pulley.b)First heat the screw at the crankshaft with the hot-air gun, then remove itwith a 19mm socket wrench.c)Put the factory supplied flange bolt in the crankshaft thread.d)Install the puller assy W40 with 4 bolts M5x20 DIN 912-10.9 to the drivebelt pulley. Then screw the bolt M12x90 DIN 933-8.8 into the puller andpull off the pulley from the crankshaft.Secure the puller with a 30 mmopen end spanner against rotation. If the pulley resists coming off youshould hit the head of the bolt M12x90 with a hammer to loosen thepulley.Maintenance Manual DG-808CIssued: June 2005 4.284.Disconnect the electric wiring coming from the magneto housing near thepropeller brake. First remove the heat shrink tubing carefully with a sharpknife.5.Remove the mounting bolts and detach the starter motor.6.Disassemble the fuel lines from the primer to the carburettor at thecarburettor using a small screwdriver to open the hose clamp. Plug theline with a 6mm bolt.7.Remove the EGT probes from the exhaust manifold with a 7 mm socketwrench (Option).8.Unplug the electrical wiring of the coolant temperature probe on thecylinder head near the probe.9.Empty the coolant system: Remove the coolant see section 4.15.2. Use abucket to catch the coolant (approx. 2 litres).10.Remove the spark plug connectors from all spark plugs.11.Remove coolant outlet (on top of the engine) from the cylinder headsusing a 4mm Allen key wrench. Seal openings at the cylinder heads withtape. Remove the hose of the coolant inlet (near the starter ring gear) andseal the inlet with tape.12.Remove the four fixing screws of the cylinder heads to the CRFP platewith a 6mm Allen key wrench. Fasten together the group of ground wireswhich are fixed by the front right screw with a wire or similar. Ifnecessary remove the front right hand side cap nut (cylinder head bolt).13.Heat the engine’s final four fixing screws at the front side of the crankcasewith the hot-air gun and unscrew them with a 5mm Allen key wrench.14.Now rotate the propeller mount a little forward and pull it from thecrankshaft.Maintenance Manual DG-808CIssued: June 2005 4.2915.Removal of the propeller brake: Unscrew the propeller brake fixing platefrom the engine‘s rear side by removing three screws with a 6 mm Allenkey wrench.16.Close the opening of the exhaust manifold with tape and seal the airfilterwith a plastic bag or similar.Removal of further attachments(don’t execute for shipping the engine forrepair or overhaul):17.Spark plugs: Unscrew spark plugs with an 21 mm (13/16’’) socketwrench. Seal the cylinder holes with tape.18.Exhaust manifold: The exhaust manifold can be removed by unscrewingthe four bolts at the cylinder outlet with a 6mm Allen key wrench. Sealthe cylinder outlets with tape.19.Air intake filter: To remove the air intake filter from the carburettorloosen the clamp at the carburettor with a small screwdriver. Seal thecarburettor intake with tape.20.Remove both coolant inlets using a 3 mm Allen key wrench. Seal outletswith tape.Maintenance Manual DG-808CIssued: June 2005 4.304.17.3Reinstallation of the powerplantReverse the procedures for removal mentioned above. Note sections 4.11, 4.13,4.15 and 4.21!Use only new selflocking nuts for reinstallation. Use Loctite 243 to secure allthreads and screws without selflocking nuts.Use new gaskets for the coolant outlet.Reinstallation of the starter ring gear1.When reinstalling the starter ring gear adjust the propeller position versusthe engine compression point according to sect. 1.11.4 via the drive belt.2.Install the screw at the crankshaft without using Loctite and tighten with atorque of 100Nm (73 ft lb). Hold the Propeller to counteract the moment.3.Tighten the drive belt according to sect. 4.12e).4.Reinstall the proximity switch and check its adjustment according to sect.1.14.15 and correct if necessary.5.Reconnect the spindle drive.6.Rig the wings to the fuselage and secure the glider. Start the engine, applyfull throttle for a short while (max. 30 seconds) and stop the engine again.7.Retorque the screw at the crankshaft with 100Nm, to accomplish this thespindle drive must be disconnected again.8.Start the engine, apply full throttle for a short while (max. 30 seconds) andstop the engine again, retorque again. Repeat this procedure until thescrew can’t be turned any more with the same torque. Normally it isnecessary to repeat the procedure 4 times. After the last retorque removethe screw, apply Loctite 243 and torque again with 100 Nm.9.Install a new selflocking nut M10DIN985-8zn to the spindle drive bolt.10.Check if the propeller position versus the engine compression point is stillin the limits. If necessary correct according to sect. 4.12 f).Maintenance Manual DG-808CIssued: June 2005 4.314.18Removal and assembly of the engine doorsIt is not necessary to cut the rubber cords for removal and assembly of theengine doors.a) Removal of the left engine door, e.g. for working at the carburettor:Extend the engine. Remove the selflocking nut at the mounting point of thehelical spring of the left engine door at the engine bay wall. Unhook thespring. Pull the spring pins out of the hinge pins. Remove the hinge pins.Retract the engine until just before the engine doors close. Move the leftengine door far enough backwards, so that you can lift the rear rubber cordon top of the propeller. Lift the engine door and lay it down on the rightengine door.b) Removal of both engine doors: Disassemble springs and hinge pins of bothengine doors. Retract the engine 3⁄4 of it ́s travel and lift both doors away.c) Assembly is the reverse of disassembly. Use new selflocking nuts.Maintenance Manual DG-808CIssued: June 2005 4.324.19Securing the propeller bolts1. Use lockwire with min. 0.8 mm (0.03 in.) diameter.2. Secure the propeller bolts as follows:a) Slide the wire through the hole in the bolthead and bend it around the head.The wire should run tangential to the bolthead so that it secures the boltclockwise to tighten it. Direct the end of the wire which was laid around thehead underneath the wire which runs through the hole.b) Twist both ends of the wire clockwise up to the other bolthead. Slide theupper wire through the hole in the bolthead and bend the other wire aroundthe head. Twist with max. 8 rotations per inch.c) Direct the end of the wire which was laid around the head underneath thewire which runs through the hole. Twist the ends anticlockwise up to thethird bolt.d) The end should be twisted min. 3 max. 8 rotation in clockwise sense. Cutoff the surplus and bend the end to prevent injuries.Caution:Don't damage the lock wire. Also minor scratches or removal of thegalvanisation have to be considered as damage.Maintenance Manual DG-808CIssued: June 2005 4.334.20Checking the Ignition unit type Ducati1)Ducati-magneto generator Type P12W150 part no. 4317140212V/150W with electronic boxes Ducati part no. 432372500The engine has 2 independent ignition circuits. It is equipped with aDUCATI electronic C.D. ignition unit with magneto generator forsupplying the electrical system of the aircraft. The ignition unit is adjustedby the engine manufacturer and requires no servicing. In case of troubleexecute the following procedures:2) The engine does not start or suddenly stops without running out of fuel.This means, that both ignition circuits are defective.a)if the starter turns at less than 500 rpm, there are no sparks at the sparkplugs. Therefore the battery must be charged enough to reach this rpm(normal starting rpm with well charged battery is approx. 600 rpm).a)Shorting cables must not be in contact with ground or with each otherwhen the ignition switch is in on position. For checking gain access tothe connector plugs at the ignition electronic boxes by removing Tyraps and heatshrink tubing. Check the resistances between wire 301(right) and ground (engine block) and wire 302 and ground (plugsdisconnected):The resistance must be infinite (ignition on) and zero (ignition off).3) During ignition circuit check before take off the rpm goes downsignificantly or the engine stops. For checking gain access to the connectorplugs at the ignition electronic boxes by removing Ty-raps and heatshrinktubing.a) Swap the connector plugs at the ignition boxes from one box to theother. Therefore you need extension wires see drawing 8E210(enclosed to this manual). If the malfunction now changes to the othercircuit, one of the boxes is defective. Detect the faulty one by mutualdisconnection of the plugs.Stop the engine before disconnecting a plug from a box.Warning:Don’t mix up the wires!Maintenance Manual DG-808CIssued: June 2005 4.34b) If the malfunction remains on the same circuit, then carry on accordingto the following instructions:b)1 Check the shorting cables see above.b)2 Checking the ignition, trigger and charging coilsDisconnect the connector plugs from the electronicboxes see 1. and measure the resistance:item pin nos. resistance (Ohm)primary ignition coil 1 76 and 77 (right) appr. 300primary ignition coil 2 79 and 80 (left) appr. 300trigger coil 1 75 and ground (right) appr. 170trigger coil 2 78 and ground (left) appr. 170With othervalues identify the defective part by the wire numbering see wiring plan8E204.b)3 Checking the air gap between trigger coils and actuators (metal plateson the magneto housing) with a gauge. The gap must be 0.45 – 0.55mm (0.018in. –0.022in.) widec) Checking the generator coil: Disconnect the engine main plug andmeasure the resistance between wires 491 and 501. It should be appr.0.5 Ohm.Warning:Starting and operating the engine with spark plugconnectors taken off can damage the ignition electronic boxes. Check forspark only with spark plugs fitted to the connectors and spark plug bodieshaving ground connection.4)Generatora) If the red generator control light shines although the engine is running:- Check the generator.Disconnect the right hand side plug (in direction of flight) from thecontrol unit. Measure the resistance between pins A1 and A2 with theengine stopped. It should be 0 up to 1 Ohm. Measure the resistancebetween pins A1 and ground and A2 and ground. It should be infinite.- If the measured results differ from the nominal values, the generator isdefective and must be replaced.Maintenance Manual DG-808CIssued: June 2005 4.35- Check the plug. Screw off the cover and check all pins visually and bycarefully pulling at each wire.If no defect can be discovered, the control unit must be replaced.b) If the generator is overcharging the batteries:Check all terminals at the control unit. If no defect can be discoveredthe control unit must be replaced.If a solar panel is installed check also the solar panel and regulator.5.Checking the ignition timingThe check is not necessary as the timing is not adjustable.Maintenance Manual DG-808CIssued: June 2005 4.364.21Installation and removal of the extension/retraction unitWhen installing the extension/retractionspindle drive proceed as follows:First, don’t tighten the bolt which connects the spindle drive to its frontmounting block. Extend the powerplant to the position (see sketch). Thentighten the bolt. The reason for this procedure is to make shure that the rubberbush in the mounting block will be twisted approx. by the same amount inupward and downward direction. False adjustment may result in cracks in therubber.900mmMaintenance Manual DG-808CIssued: June 2005 4.374.22Calibration of the fuel display in the DEI-NT(only necessary with replacement or repair of the DEI-NT)1. Preparations:Drain the fuselage tank using the built-in electrical fuel pump.Therefore disconnect the fuel hose at the lower side of the mechanicalfuel pump and stick it into an appropriate can.Switch on the ignition and wait until the tank is drained.Note:To achieve maximum offset-accuracy it is necessary to keep thetank filled until starting these preparations.Levelling: glider positioned with main wheel and tailwheel on a flatsurface.2. Calibration procedure:Change to the set up screen in the DEI-NT by pushing the selector knob(right hand side) until the DEI-NT beeps twice for 2 times.The following screens will appear: Flight log, Set upSelect the following menu point via the turning knob:EMPTY TANK CALIB.(ration): Calibration of the fuel gauge withempty tank. Push the selector knob, N will be displayed, rotate theselector knob, Y will be displayed. Push the selector knob to executethe calibration.Fill the tank completely and select the next menu point:FULL TANK CALIB.(ration): Calibration of the fuel gauge with fulltank. Push the selector knob, N will be displayed, rotate the selectorknob, Y will be displayed. Push the selector knob to execute thecalibration.Push the selector knob until the DEI-NT beeps twice for 2 times toreturn to the flight screen.4.23Further DEI-NT settingsChange to the set up screen in the DEI-NT by pushing the selector knob (righthand side) until the DEI-NT beeps twice for 2 times.The following screens will appear: Flight log, Set upSelect the menu point via the turning knob:Calibration of the starter motor speed to turn the propeller into retractionpositionSTARTER SPEED: % of the normal starter motor power to turn the propellerinto the position for retraction (ignition switched off) – standard value 35%,adjustable between 0-49%.Maintenance Manual DG-808CIssued: June 2005 4.38Calibration of the primerPRIMER DOSE: % of the max. amount of fuel injected by the primer, max.99% - standard value 99%.(With 0°CHT. the adjusted amount of fuel will be injected. The amount of fuelwill be reduced linearly to 0 at 40° CHT).PRIMER DURATION: Post starting injection of the primer, max. 99% of thetime programmed in the control unit (40 seconds), standard value 99%Activation or deactivation of the electrical propeller brake (Option)PROP BRAKE: Activation of the electrical propeller brake (Option), Push theselector knob, N will be displayed, rotate the selector knob, Y will be displayed,the propeller brake is activated. Rotate the selector knob N will be displayed, thepropeller brake is deactivated. Push the selector knob to save this adjustment.Notes: If no electrical propeller brake is installed this function must bedeactivated, otherwise failure messages will be displayed.Activation or deactivation of the low temperature warningFREEZE WARNING: Activation or deactivation of the warning message.Adjustment similar to Prop Brake. You may deactivate this warning in case nowatertanks are installed. When deactivated the OAT screen will still blink at lowtemperatures.Activation or deactivation of the acoustic warning signalsJOINT WARNING OUTP: Activation or deactivation of the signals to draw thepilots attention to the messages. Adjustment similar to Prop Brake.Note:The signal for the stall warning will not be deactivated.Download of flight log and service dataFLIGHTLOG→PC: Push the selector knob, N (no) will be displayed, rotate theselector knob Y (yes) will be displayed, push the selector knob to reset start thedownload of the recorded data. The PC must be connected to the serial interface(socket close to the radio).Download instruction can be found in the amendment to this maintenancemanual.Resetting the time until the next 25 hour maintenanceRESET MAINT. TIMER: Push the selector knob, N (no) will be displayed,rotate the selector knob Y (yes) will be displayed, push the selector knob to resetthe time to the service-interval (25 hours).Push the selector knob until the DEI-NT beeps twice for 2 times to return to theflight screen.Maintenance Manual DG-808CIssued: June 2005 5.15Weight and balance1.Assemble the glider completely with gear down.2.Empty fin ballast box and water ballast tanks.3.Place scales under the tailwheel and if suitable scales are available under themain wheel.4.The fuselage must be levelled so that the top of the aft fuselage boom has atail-down slope of 1000 : 37.5.Read weight of tail wheel: W2, be certain the wings are level and hold so thatno load is applied. Read W1 if suitable scales are available, otherwise seenote below.6.Measure the distance between perpendiculars through points a and b. (Seefigure, next page).Caution:The distance a may change with different masses due to deflection ofthe landing gear.Note:The total mass M may be determined by weighing and adding W1 andW2 or by weighing and adding the masses of all components.Using the empty mass and the values determined above, calculate the C.G. asfollows:C.G. empty:XSL: XSL= W2L• b/ML+ aML= empty mass = W1L+W2LW2L= load on tailwheel (empty)The empty weight includes all accessories but excludes pilots and parachutes.Remove loose objects and any removable trim ballast from the cockpit.C.G. in flight:XSF: XSF= W2F• b/MF+ aMF= flight mass = W1F+W2FW2F= load on tailwheel (flight mass)The flight mass includes empty weight items plus pilot, parachute, trim ballastand all items needed in flight (barograph, camera, cushions, etc.). In addition,the rudder pedals and seating position should be adjusted as in flight.Maintenance Manual DG-808CIssued: June 2005 5.2Datum (BE): Wing leading edge at root ribLevelling line: Aft fuselage boom slope 1000:37 (tail down)Moment arms of pilots and equipment see flight manual sect. 6.9Empty weight C.G. measurementsAfter the addition or deletion of equipment or accessories, repairs, painting, orany change in the aircraft that could influence the weight and balance; a newweight and balance must be carried out. Aircraft certified as Standard Categorymust have the weight and balance carried out by a licensed Airframe Mechanic.Empty weight C.G. range is determined by reference to the diagram in sect.6.8.8 of the flight manual. If the C.G. is out of limits, adjustments may be madeby ballasting or by relocating equipment or accessories.The result has to be entered in the flight manual section 6.8.7 and in the aircraftlogs. If the min. cockpit load or the max. flight mass without waterballast havechanged, the new values are to be entered in the cockpit placard.Weight and balance must be carried out at least every four years.C.G. shift due to extension of the enginesee flight manual section 6.9bxW2pattern 1000:37WBEMaintenance Manual DG-808CIssued: June 2005 6.16Instrumentation and accessories listAir speed indicator(0 - 300 km/h, 165 kts)ManufacturerTypeCertification No.Winter 6 FMS 4(diam. 80mm) TS 10.210/150-300 km/h Ident.No. 64213690-160 kts Ident.No. 6423369Winter 7 FMS 4(diam. 58mm) TS 10.210/190-300 km/h Ident.No. 74213690-160 kts Ident.No. 7423369The airspeed indictor must have colour coded speed ranges marked as indicatedin the flight manual section 2.3.AltimeterManufacturerTypeCertification No.Winter 4 FGH 10 (diam. 80mm) TS 10.220/461.000-10.000m Ident.No.41103.000-30.000ft Ident.No.4330Winter 4 FGH 20 (diam.58mm) TS 10.220/471.000-10.000m Ident.No.4220Winter 4 FGH 40 (diam.58mm) TS 10.220/481.000-20.000ft Ident.No.4550Or any other TSO C 10b specified and approved altimeter with fine rangepointer 1 turn max. 1000 m, 3000 ft.Harness (seat)ManufacturerTypeCertification No.Gadringer BAGU 5202 G40.070/32SCHUGU 2700 G40.071/05rubber coated adjuster barsSchroth 4-01-0.104 40.073/11Maintenance Manual DG-808CIssued: June 2005 6.2CompassManufacturerTypeCertification No.PZL B - 13 FD 19/77Ludolph FK 16 10.410/3Airpath C 2300Hamilton H I 400 TSO C 7c Type146 MFK 1 (only as additionalequipment.)The compass should be compensated in the A/C. A deviation table must beinstalled if deviation is more than 5°.VHF transceiverManufacturerTypeCertification No.Dittel FSG-40 S 10.911/45FSG-50 10.911/71FSG-60 M 10.911/72FSG-70,71 M 10.911/81FSG-90 0.911/98JTSOFSG 2T LBA.0.10.911/103JTSOBecker AR 3201-(1) 10.911/76AR 2008/25 (A) 10.911/48AR 4201 JTSO-2C37 D, ED-23AFilser ATR 720 A 10.911/74ATR 720 C 10.911/83ATR 600 O.10.911/106JTSOATR 500 LBA.0.10.911/113JTSOor other instruments certified for aircraft use according to TSO or JTSO orETSO standards may be installed.Note:Only radios with diameter 58mm (2 1⁄4 in.) can be installed at the assignedplace in the console below the instrument panel.VariometerManufacturerTypeCertification No.Winter 5 StVM5 (Diameter 58mm) TS 10.230/14+5 m/s Ident.No. 5451+1000 ft/min Ident.No. 5452+10 kts Ident.No. 5453Winter 5 STV 5 (Diameter 80mm) TS 10.230/13+5 m/s Ident.No. 5251+1000 ft/min Ident.No. 5252+10 kts Ident.No. 5253Maintenance Manual DG-808CIssued: June 2005 6.3Turn and bank indicatorManufacturerTypeCertification No.ApparatebauGauting WZ-402/31 12 V 10.241/8Outside air temperature gaugeincorporated in the DEI-NT see belowEngine instrumentation(RPM, fuel, CHT, voltmeter, engine elapsed time, outside air temperature,EGT as an Option)ManufacturerTypeDG Flugzeugbau DEI-NT-DG808CInstruments which are not part of the minimum equipment:Transponders:Transponders certified for aircraft use according to TSO orJTSO or ETSO standards may be installed.Other instruments and equipment (eg. variometers, gliding computers orflight data recorders):Instruments and other equipment may be installed if they do not in themselves,or by their effect upon the sailplane, constitute a hazard to safe operation.Caution:If additional instruments or equipment are to be installed afterproduction of the glider, it must be assured that they will be installed in theplaces provided by the design. If installed in other places it must be assured thatthey are secured safely.Electrical instruments and equipment must be connected via appropriately ratedfuses, the power consumption of each single part should not exceed 3A.After installation raise a new weight and balance report.Maintenance Manual DG-808CIssued: June 2005 7.17List of special toolsA Special 13 mm wrench for front tailplane mounting screw (supplied withthe glider) (W 35).B Pin 6 mm diameter with handle for wing tip mounting (W 36) (only withoption wing parting)C Open end spannersmm mm mm mm7 10 17 308 13 199 14 22D Allen key wrench: 5 mm, 6 mm, 8mm, 10mm, 12mmE Wrenches for slotted nuts (hook spanner) according to drawing W 51(encl.) (for the bearings of the upper drive belt pulley)F Two steel rods dia. 4 mm (5/32 in.) appr. 70 mm (3 in.) long (aileroncontrol stops)G Spring balance max. reading 50 N (11 lbs.)H Nicopress tool 64 – CGMPI Hose connector TS 16 (to drain coolant) (supplied with aircraft serviceset)J Torque wrenchTorque range 0 - 150 Nm (o - 110 ft lb) with socket wrench 19 mm (forassembly of the drive belt pulley and the magneto housing of the engine)K Torque wrenchTorque range 0 - 50 Nm (0 - 370 ft lb) with socket wrenches 10, 13, 17,19 mm and 21 mm (13/16 in.) for sparkplugs and Allen key inserts 3, 4, 5,10 mmL SOLO engine tool set incl. puller assembly for magneto housingMaintenance Manual DG-808CIssued: June 2005 7.2M Wrench for spark plugs 21 mm (13/16 in.)NWithout Option BBSA Slipping/centrifugal clutch:Puller assembly forlower drive belt pulley according to drawing W40Option BBSA Slipping/centrifugal clutch:Puller assembly for lowerdrive belt pulley according to drawing W60O To fill the wing tanks: Hose with outside diameter 25 mm (1 in.) appr. 2m (6.56 ft.) long.P To fill the fintank: Z27 (Funnel with clear PVC hose inner diameter 12mm (.47 in.) 1,7 m (5 ft.) long and hose connector GS12)Q Test adapter W59 with 0.5m PVC hose 5mm inside diameter to test thecoolant pumpR Refuelling hose for fuselage fuel tank Z155/1S Crimp tool for clamps XO for 6mm bungee (bungee for retaining cable)Maintenance Manual DG-808CIssued: April 2009 TN800/35 8.18PartlistIn this list you will find only parts of the powerplant, the electrical system andcontrol surface sealings and turbulators.Please find the part no's of the control-system parts and of the metal fittings ofthe powerplant in the following diagrams.8.1Parts for the powerplanta)necessary for the 25 hours inspection60510806 Spark plugs Bosch W5AC electrode gap 0.5 mmCaution: The removable cap must be secured with a little bit of Loctite 638 onthe thread prior to installation40050360 Spark plug S36 (Bosch W5AC electrode gap 0.5 mm) with screwcap fastened to the thread by crimping, marked with a red dot ofpaint on the insulator60507569 Fuel filter elbow or60507571 MANN-fuel- filter 500009180 WK 31/2(10)60500150 Gaskets for exhaust manifold (2 pieces needed)60500142 Air intake filter70002200 Oil for airfilters with cottonfabric K&N 99-05046b)Spare parts60510821 Spark plug connector Bosch 0356351032 1kΩ60500127 Nut for spring coupling M 8 for exhaust muffler60500128 Spring for spring coupling M 860502500 Starter motor: DENSO 128 000-1671 12 V60500155 Gasket for coolant outlet60504012 Drive belt Poly Chain PC 8MGT 2400-36 with smoothed back59332050 Front bearing for upper pulley 32205B59320320 Rear bearing for upper pulley 320/32X52200054 Securing washer 20 DIN 462 for upper pulley front bearing30002028 Special grease for upper pulley bearings SKF LGMT339001026 Exchange kit nuts and bolts for 400 h overhaul40050472 Gas spring for ext.-retr. drive S47/2 with Ultra-bush60000182 Gas strut for muffler frame E1 E1-76-040-130/150N60505007 Ext.-retr. spindledrive type Stross ATL10 modified with forks8M230 and 8M33360000330 Rubber mount at engine hinge axis Ultrabuchse 011828840872873 Brake pad for propellerbrake (glued to mounting bracket)60001115 Clamps XO for 6mm bungee (bungee for retaining cable)Maintenance Manual DG-808CIssued: April 2007 ÄM 800-17-07 8.260001201 Electric water pump Webasto U4810 modified60510565 Probe for coolant temperature TG 150/260504051 Radiator KTM VW 0095Rubber mounts for radiator60000275 2 pieces Rundlager Type B (upper mount)60000262 1 piece Rundlager Type A (lower mount)39001018 Service kit cooling system hoses60507550 Drainer CAV 110 (1/8" NPT)Warning:Replace the sealing ring of the drainer against partno. 60504402prior to installation60504402 Sealing ring for drainer CAV 110 (for automotive fuel)60507561 Electric fuel pump Facet 4010660507558 Refuelling pump KAVAN 12 V up to ser. no. 8-37260507562 Refuelling pump Facet 60106 from ser. no. 8-373 on60507571 MANN-fuel- filter 500009180 WK 31/2(10) for refuelling pump40873071 Fuel distributor 8M307 with filter for primer valve and restrictionfor excess fuel line60000527 Fuel cock KH 1072 T60507607 Coupling for fuel filler hose KL-006-0-SL00760503070 Primer-valve IWP06945001604 Full tank sensor60000103 Fuel hose PU hydrolyse and microbe-resistant 6x1x860000102 Fuel hose PU hydrolyse and microbe-resistant 8x2x12Option wing tanks with electro-magnetic valves60507600 Coupling for fuel wing tanks (at fuselage) KL-006-0-SL00960507601 Coupling for fuel wing tanks (at wing) KL-006-2-WR51340872591 Electro-magnetic valve MA242-004V27SAH12/00SWMaintenance Manual DG-808CIssued: June 2005 8.38.2Parts for the electrical system60510891 Battery 4E15 6V, 10 or 12Ah equipped with screw - terminals40876200 DEI-NT-8E62040876210 Control unit-NT 8E62160510464 Limit-switch engine retracted and engine extended 164-57460510484 Manual extension-retraction switch MTG 206 S60510854 Key switch 3 Pos, 2 Pol KL09-1908KA (Master switch)60510370 Press-button SECME 07 17801 21 for starter up to ser. no. 8-34460510372 Press-button DJET 07.17502.21 for starter from ser. no. 8-34560510375 Press-button 12G2904 for test of second fuel pump and forrefuelling pump60510385 Circuit breaker ETA 2A60510386 Circuit breaker ETA 3A60510436 Fuse 535257 60 A for batteries60510440 Fuse 250V 0.2A 5x20 m for fire warning light60510550 Proximity switch Insor INCT 121240871350 Proximity switch ready assembled with wiring and plug60510796 Socket BSB 12 (in main bulkhead)60510797 plug BSK12 for socket BSB 12Maintenance Manual DG-808CIssued: June 2005 8.48.3Control surface sealings and turbulators1. Wings - upper surface30003125 Mylar sealing 0.19 x 22 mm without glue, curved70000253 Tesafix No. 4965, 9 mm wide, 50 m roll glue film70000229 Tesafilm 4104 white, 19 mm wide, 66 m roll PVC tape2.Wings - lower surface30003132 Combi sealing 43/19/06, 2 x 7 m (23 ft.)30003131 Combi sealing 38/19/06, 2 x 1.45 m (4.76 ft.)or30003300 Noppenband 10m roll (dimple turbulator tape)70000229 Tesafilm 4104 white, 19 mm wide, 66 m roll PVC tape3. Flaperons (sliding surface and internal sealing)30003136 Teflon-glass fabric 0.08 x 38 mm, 33 m roll selfadhesive4. Horizontal tailplane30003129 Zig-zag turbulator tape 60 degree 0.4 mm thick30003128 Upper surface: Mylar sealing 0.19 x 30 mm without glue, curvedleading edge scarfed ,2 x 2,5 m (9.2 ft.)70000253 Tesafix No. 4965, 9 mm wide, 50 m roll glue film70000229 Tesafilm 4104 white, 19 mm wide, 66 m roll PVC tape5. Vertical tailplane30003132 Combitape 43/19/06, 2 x 1,1 m long70000295 Internal sealing: 3M Scotch V-seal weatherstrip Cat.Nr.2101white, 22mm, 5.2m roll (V-tape)Maintenance Manual DG-808CIssued: June 2005 9.19Enclosures9.1Equipment list1 kg = 2.2046 lbs 25.4 mm = 1 in.Note:If this list is not filled out, you will find a similar list in your aircraft logs.Parts of the min. equipment are to be chosen from sect. 6 of the maintenancemanual.Subjecttypemasskgarmsmmdate ofinstallationdate ofremovalAirspeedindicatorAltimeterVariometerel. VariometerCompassRadioEngine Indicatorand OAT gaugeDEI-NTDG-808CC. G. hookG 88forward hookE85Seat harnessMaintenance Manual DG-808CIssued: June 2005 9.29.2Checklist for checks and maintenance workaccording to sect. 3.5.1 of the maintenance manualh 25 50 75 100 125 150 175 200 225 250 275 300123456789101112131415161718192021222324252627282930313233executedbyplacedateenginehrssignatureEach item shall be signed off or the data which was determined shall be entered.The list is valid for the engine hour range:..........h - ..........hDG-808C Ser.no. 8-.......B.......

# Zugfederltension spring



# 77x58x10,3x1,3 zn

512513**65t23J2~**

.0



# Feder 51 2512

Halse st2413



# Zugfederltension spring 55x12x1 6512311 

# Seitensteuerung

rudder control

# BR19~__ , i 

# 4L1313

. 6

6



# ______ _ __ 6,

. ,



# i'



# BR1B

8LI612

8L1613



# 7 

# Kugelgriff schwarz!

ball handle black



# R62/3 

# V 

# /7'# 8L1611



# W

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# ~"'5135

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# 1'.)2. 

# 01\) 

# 5:8

01 5125 bJ1



# St31

WOlbklappensleuerung

wing flap control

68t9 65123

Quersleuenung 

# I aileron control



# St2 BR2712

zur Spornradgabel/

towards tailwheel fork



# lY

!

!



# i 

# Splintbolzeniclevis pin

# _~ ....

# ~:,~61~I:~~:~::n

. . . . . .. ..... ... 6,4 DIN9021 

# Stzn

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# Splint 1,5x12zn

BR2712

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6811



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# Bremsklappensleuerung



# airbrake control



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81211



# 6St205

BSt10B/1 + 

# 12

Tesaband 651



# 30 breit als Sichenmg

textile tape 

# 30mm wide as securing

# J~\'**~\** Trommelbremse

for drum brake

Option Scheibenbremse

for optional disc brake 

# 0.0 

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# 1r;,'3

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# Schleppkupplungen, Wasserballastanlage

tow releases, waterballast system

to

# ~ III 

# Q.. 

# 0,



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# Diagramm 5

diagram 5

Ausgabe: November 2004

Issued: November 2004

# waterballastsystem in the wings waterballastsystem in the fin

check valve 8F75 (only 75 L 

# bag) 8FE30

chain-link C 3 mm I

(.12 

# in.) II II V j \ \

# ~



# Nylon cord 3mm 

# (.i2in.)

8F71 751; 8F73 601 venJion:Competition;



# 8F40 SOl 

# version: CIBSSic waterbag 

# glued 

# with Silicone

onto valve



# wrap 

# 3x Tesaband 651 

# at the PA tube 

# Bx1x730_



# ventilation "

place for the hose clamp around waterbag

hose clamp 25-20



# dump valve drive at fuselage

dump valve in wing compression spring O,75x9x50 i=11

# niPPle23B~jUstingscrewM6

fuselage 

# \,A;J II 2R1111

# ~p;,;~~'**;';ri~g'1,** 1x9,6x62 i=10 1.4310



# tow releases

waterballast control handles in front cokpit fin tank

BR24B11 

# with optional nose tow release without nose tow release 

# ;::W_20IlA**~**

nippel27D



# shift handles Suntoul



# all dimensions in mm; 25,4mm= 1in. 

# -, PVC tube 12x4.5



# with webbing

PVC tube 12x1.5

tube 

# dimensions

(inner diameter x thickness)



# diagram 5a**i~sued** 

# April 2007

AMBOO-17-07 waterballst system

tow releases cable dia.1 ,6 mm MIL-W-83420 If 

# A

Abnahmen tar den statischen Druck I 

# probes for static pressure

Rumpfschale I Sitzwanne I seat shell

-'----'--- shell

Wssserabscheider I

water precipitator

analog zu Stat h I

similar to Sta. h

# )(6~3712 in Unterseite Rumpfspitze 

# I

probe 6R3712 below fuselage nose Seitenflosse I fin

TE Pitot

# ~~: I 

# probe 

# IZJ

spazi.1 TE DOse 43

.

# ~~ . 

# S lS

t

# special TE probe

,

# -·-·-b--·-·-·-·-"j~;·1 

# •**geschl~** I closed

Multi DOse ist Option, serienmaBig Adapter SQs tor,'normale TE- DOse

Leihmgen Pilot M und stat. M entfallen " ( (

Multi probe is optional, standard is adapter SP5(fo,t normal TE probes

lines Pilot M and stat. M are not

.



# ----,

AusgleichsgetaBe unter

der SauerstoffflaschenrOhre f



# for variometer flasks below oxygen botHe housing

VVichtiger Hinweis: Der Fahrtmesser dart nur an den vorderen Druckabnahmen Stat V + Pilot V angeschlossen werden. 

# I

Caution: The airspeed indicator must 

# be connected to the front probes Stat V + Pitol 

# V.

Die Anschlusse der Multi Duse sind zum AnschlieBen von Variometer- und Rechnersystemen bestimmt I

The multi probe is intended to connect variometers and gliding computers.

Aile Schltuche PVC weich 8x1 

# ,51 all lines soft PVC 8x1,5

# c~ 

# >**G>cn~**

I 

# 6f m

# ~3'fil COm::J



# 00'2:**~ ~**  

# i&i&

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# Cilm

mm mill



# c: 

# 3 

# Cils:

2**~**



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# 3 3



# ;:!I! '" 3

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# .., _. 0..,

00



# <no

<n

# Reifendruck 2 bar

Tyre pressure 29 psi

above tailwheel 12 V near the

socke t Typ: DG-808C

W.Nr.:



# fire proof placard at the

main fusela g e bulkhead

Bauteil Nr.:



# p art No.’s at all com p onents

Benzin min. 95 Okt. Zweitaktöl

petrol min. 95 ROZ 

# 50:1

two stroke oil 

# 21 l

screen print near fuel filler

Reifendruck 3 bar

Tyre pressure 47 psi

on the right wheel door front

Drainer on the right wheel door

r ea r 

# placards DG-808C Classic

diagram 7a

issued August 2005 Tankpumpe

Refueling pump 

# at the main

fuselage

bulkhead near

the button

13 10 11 12 zu Brandhahn auf

closed fuel cock o p en 

# 9

14 15

16 17

18

20 L 8 5 0 –5 –10 -14 19 Option near the switch Flügeltanks

wingtanks f uel pump

test 

# 1

5 Fire 

# 2 Primer

auto

off



# 6 Gepäck max. 15 kg

baggage max. 33 lbs.

at the main fuselage bulkhead

Vario

Radio

XPDR

Gyros

4 stat

TE

man. 

# 3 7

on the left wheel door front

Sollbruchstelle max. 6600 N

rated load max. 1455 lbs

. 8 Propellerbrake



# 25 intern

off

extern 

# 22

FLIGHTLOG 

# 23 24 DG Flugzeugbau GmbH

type: DG 808C Classic serial no: 8-

year of construction:

Maximum airspeeds km/h kts.

Winch launch 150 81

Aero-tow 190 103

Manoeuvering V A 

# 190 103

Rough air 190 103

Max. flap extended speed +8° +5° 190 103

Landing gear operating 190 103

Maximum speed V NE 

# 270 146

Max. flap extended speed L 150 81

Powerplant extended 190 103

Powerplant extension-retraction 100 54

Approved aerobatic manoeuvres ( only without waterballast and

with engine retracted)

pos. Loop, Stall Turn, Lazy Eight, Chandelle, Spin

Maximum mass: 525 kg ( 1157 lb.)

Loading chart

Cockpit load ( parachute included )

maximum 110 kg 242 lbs

minimum kg lbs

With lower p ilot wei g ht necessar y ballast must be added.

Preflight inspection

1. Lead ballast ( for under weight pilot )?

2. Parachute worn properly ?

3. Safety harness buckled ?

4. Seat back and pedals adjusted ?

5. All controls and knobs in reach ?

6. Altimeter ?

7. Dive brakes cycled and locked ?

8. Wing flaps in take off position ?

9. Positive control check ? (One person at the

control surfaces).

10. Trim ?

11. Canopy locked ?

Additional checks before self launching

12. Fuel level ?

13. Fuel Cock open?

14. Canopy open – propeller clear ?

15. After starting the engine – close canopy.

16. Check engine RPM.

17. Check both i g nition circuits

.

Altitude in [m] 0-3000 4000 5000 6000 7000 8000

V NE 

# IAS km/h 270 256 243 230 217 205

Altitude in [ft] 0-10000 13000 16000 20000 23000 26000

V NE 

# IAS kts. 146 138 131 124 117 111



# on the instrument p anel 21 Starter

Throttle



# 26 Reifendruck 2 bar

Tyre pressure 29 psi

above the tail wheel 12 V near the

socke t Typ: DG-808C

W.Nr.:



# fire proof placard at the

main fusela g e bulkhead

Bauteil Nr.:



# part No.’s at all components

Benzin min. 95 Okt. Zweitaktöl

petrol min. 95 ROZ 

# 50:1

two stroke oil 

# 22l

screen p rint near the fuel filler Reifendruck 3 bar

Tyre pressure 44 psi

on the right gear door front

Drainer at the left gear door

rea r 

# placards DG-808C Competition

diagram 7b

issued August 2005 Tankpumpe

Refueling pump 

# at the main fuselage

bulkhead

near the button 13 10 11 12 zu Brandhahn auf

closed fuel cock o p en 

# 9

14 15

16 17

18

20 L 8 5 0 –5 –10 -14 19 Option near

the switch Flügeltanks

wingtanks f uel pump

test 

# 1

5 Fire 

# 2 Primer

auto

off



# 6 Gepäck max. 15 kg

baggage max. 33 lbs.

at the main fuselage bulkhead

Vario

Radio

XPDR

Gyros

4 stat

TE

man. 

# 3 7 Sollbruchstelle max. 8250 N

rated load max. 1820 lbs

.

on the left gear door front

8 Propellerbrake



# 25 intern

off

extern 

# 22

FLIGHTLOG 

# 23

Altitude in [m] 0-3000 4000 5000 6000 7000 8000

V NE 

# IAS km/h 270 256 243 230 217 205

Altitude in [ft] 0-10000 13000 16000 20000 23000 26000

V NE 

# IAS kts. 146 138 131 124 117 111



# on the instrument p anel 24 DG Flugzeugbau GmbH

type: DG 808C Competition serial no: 8-

year of construction:

Maximum airspeeds km/h kts.

Winch launch 150 81

Aero-tow 190 103

Manoeuvering V A 

# 190 103

Rough air 190 103

Max. flap extended speed +8° +5° 190 103

Landing gear operating 190 103

Maximum speed V NE 

# 270 146

Max. flap extended speed L 150 81

Powerplant extended 190 103

Powerplant extension-retraction 100 54

Approved aerobatic manoeuvres ( only without waterballast and

with engine retracted)

pos. Loop, Stall Turn, Lazy Eight, Chandelle, Spin

Maximum mass:

18m wingspan 600 kg ( 1323 lb.)

15m wingspan 540 kg ( 1190 lb.)

Loading chart

Cockpit load ( parachute included )

maximum 110 kg 242 lbs

minimum kg lbs

With lower pilot weight necessary ballast must be added.

limits for use of the fin or fuselage waterballast tanks

°C 13.5 17 24 31 38 minimum

ground temperature °F 56 63 75 88 100

m 1500 2000 3000 4000 5000 maximum flight altitude

above GND ft. 5000 6500 10000 13000 16500 Preflight inspection

1. Lead ballast ( for under weight pilot )?

2. Fin ballast tank emptied or correct amount

filled in?

3. Parachute worn properly ?

4. Safety harness buckled ?

5. Seat back and pedals adjusted ?

6. All controls and knobs in reach ?

7. Altimeter ?

8. Dive brakes cycled and locked ?

9. Wing flaps in take off position ?

10. Positive control check ? (One person at

the control surfaces).

11. Trim ?

12. Canopy locked ?

Additional checks before self launching

13. Fuel level ?

14. Fuel Cock open?

15. Canopy open – propeller clear ?

16. After starting the engine – close canopy.

17. Check engine RPM.

18. Check both i g nition circuits

. 

# 21 Starter

Throttle

# Triebwerk

powerplant BM251

# ,,~;~~~ M6x22 DIN 7984 

# Diagramm 8 diagram 

# 8

BM252/1 M6x20 DIN 912

- B.Bzn

MBx16 DIN 912

- B.6zn

# V'Y·'\4~I-e-~~BM25212

siehe Zeichnung

BM110**:----+~\-**



# see ",Q'W" "'.

62

BM269

# BM115iff~~~~:rIl--M_!IDIN Zahnriemen

drive belt**JlL~~M** 

# BM13B



# ::: Jl----RR12811

Rundlager Typ A



# rubber mount

KOhler KTM VWO095



# radiator BR12811

M6 DIN 9B5.B

SchnittA-A

,

BM169 BM171 

# i

Rundlager Typ B ;---

_ 

# rubber mount

# 5'3DIN125~_ M5X55LN9037',

M5SSN003

# ~~',**~';~'!j~** M5DIN9B5-8.6zn '

__ - BM254



# Anlasser



# starter motor

BM229/1 ohne BBSA Kupplung

with BBSA clutch

BM22912 mit BBSA Kupplung

without BBSA clutch 

# Propeller Bremsen

BM276



# Ausgabe August 2005

issued August 2005 KOhlsystem DG-808C

Coolant system

Vorderansicht:

front view:



# 5

Schlauch 4 langs

aufgeschnitten

und aber Nr.1

als Scheuerschutz

an ZOndbox mit 240

Tyrap 4,8x190 

# @

befestigt

hose 4 cut langswise

and slip over Nr.1 to

prevant chafing

fix at ignition

box, with Kahler

radiator

KTM

VW0095

engine

Solo

2625

tyrap 4,8x190 

# 6

Alu-Rohr 16x1x60

tube GS16 o 

# Diagramm 9

diagram 9

Opel GM 08-26888 8974835

o



# @ L=60

KOhlerverschluB

radiator cap KTM 4.9090.01

KOhlwasserauslaB

cooling water outlet

8M251



# 3 8

8M253 8M252

KOhlwassereinlaB

cooling water inlet 

# ®

_---'"r-Wasserpumpe

waterpump Webasto U4810

Ausgabe August 2005

issued august 2005

# m

boll M 1 OX60 LN9037 

# it

nul Ml0 DIN9B5-a ZN :J 

# washer 2x 10,5 DIN125 SI zn (with BM233/1 up to issue g) 

# !!!.

wash 10,5 DIN125 SI zn (with BM233/1 issue hand BM333 see TMBOO 35) 

# g

,

bon M6x90 DIN931-B.8zn gas slrul 

# S4712 b II MBx50 DIN 7984 B 

# 9z bo M6x14 DIN 79B4 B,9zn 

# i[

nul MB DINBB5-B zn 0, n 

# iil

washer 6 4 DIN9021Stzn nut MB DIN 9B5.B zn Sl

,

# l'l;L~~~~d::l~~~~w:aS:h~e:r:B~'4~D11:N~I:2:5~S~I~zn~~~~~~~::::::~~==r;g.**~** 

# c:

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nulMB

DIN9B5-azn



# w8sher6,4 _ !P.. ;::::;.:



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# \

boll M6x25 \ \ :

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nulMB

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washerB,4

DIN9021 Stzn



# gr securing washer 

# 5i 13 DIN 432 SI

Co

# ~**~** 

# '" BM254 

# ser. no.

boll MBx45 LN9037

nul MB DI N9B5-B ZN

washer 2x B,4 DIN125 51""n

up 10 ser. no. 8-402,

ser. no. 8-404 up to 406 an,

BM122 \/\IIlh

# B~33/1 issue h as spare pi



# , ' spindledrive Slross ATL 10 BM1B4

BM230

boll M12x55 DIN 931-a.B zn

nul M12 DIN 9B5-B zn

washer 2x 13 DIN 125 SI zn

ser. no. B403 and ser. no. B407 up to 409

and from sar. no. 8-411 on Q.



# instead of BM233/1 and boll MBx45 

# r2j'

o

o

co boll MI2xl,5x90DIN960-B.Bzn up 10 se no. B402,. ser. no. B404**UPI0406~nd8-410.** 

# (sTeTNB00-35)

.f-

---- 

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# 'Iil-**!~**

# ~,**~ ~** 

# DG-808C

Einbau des Kraftstoffilters

Installation of the fuel filter

E

E

a



# ..,. 

# !'i Diagramm 11 C

Feder VD-206 G-02

spring

Ty-rap 186x4.8

Ty-rap 186x4.8 gegen

Verrutschen des Filters

in der Halterung

to secure the filter in the

holder

Filter gerade I straight

Die Schlauchlangen sind gleich fOr beide Filter

the length of the hoses is the same for both filters



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# <;g



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# ~ 

# / X;



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# Ausgabe Juni 2005

issued June 2005 DG-808C Diagramm 11d

Kraftstoffanlage mit FACET Betankungspumpe 

# I

fuel system with FACET refuelling pump

Serienwraion 

# flItandard YenIion

(bel Option FJOgaltanks alaha BEP210



# with optional 

# wing tanks &eEl 

# 8EP21 OJ

,------------------------------,



# i 

# Filar MANN 500009180 i



# : Vv'K 3112(10) Batankungspumpal

i 

# !refuelling pump I



# : ElnfQlllw lung Facet 60106



# :fillercou ing

I 

# KL 006-2 LOO7

Tankstulzen

fuel 

# "liar

aRlO



# 35



# , Tankdeckel



# "Iler cap

4R87

EW6x1-R 118

Cnllllftungsieitung

Nyloorohr 

# 6x1

vent line

nyIonhoee ex1 Luflfilter

KndbIlDffverlBiler mit Primervenlil air 

# intake filler

mulll-fual-oonnactor with pr1mar-vaIYa

(8M30B/2)



# BM307/1

# l1ctI~~nI

my



# Filter-QG Nf. 80507569

# :~~sOODomo WK311210)



# Y



# 1.':""""""'" 110

1300 

# v"'_

carburettor

Ringnippel881.0304

rlngnlppel

# -~ Rumpf 

# ""''''

Tank



# fa" 8R144

# F:WJ:g~08



# ,-

__

# 4R3_W~'.\ 

# 605\1

1100



# 4R4D11 ANQ14-1D 

# ,

, 270 

# , Schnaldrtng



# GOIzdSLl. Krafbiloffpumpe

OberwurfmullBr 300 

# fuel pump

GOIzmSLl. 

# Facet40108 5R200I1



# I comprussion-typa



# Drainer CAV 110 

# .. ", 

# ,

350 

# , 9IlO



# ,

Kmftstoffschlauche I 

# fuel

# hoses:'::::~~=J4'JC:~ PU hydroly8e und mikrobenbealandig 

# 1

PU hydrolyse and mla'Obe 

# resI!Itant

ex1,5X9 ex1,5X9**KXXXXXX3~** 

# wie gelief8rt 1 

# mil Melallgellechllhrzogen 

# f

a& 

# delivered with metal shield

"",12 

# Brandhahn KH 

# 1072T - T I/A



# mit Gewindel:llile 

# 114"-9 W!Irth 06Q94914 (AUllllllngewinde)

und GewindIJIOlia 

# 1f4"-8 W!lrth 06995914 (Innangewlnde)

emergency shut 

# off 

# valve with 

# hose 

# connectors

VerbindunCJBStC!cke und Klemmen

Fitlinas and damDB

8 WinkelstClc:k VllSAG 08 1/8" Messing {elbow, brass

t FacetEinllCl1raubstutzen41199/nippie

u Nlpppal SAG 06/R1/8" 1 nipple



# m I1lter 8chrumpf8chlaucl1, 30mm**I~** 

# f rad 

# heat shrink**wbi~** 

# n blauer 8chrumpfllchlauch, 30mm lang 

# f blue heat shrink wblng

w 

# Ohrklemme 1131 

# clamp

x Schlauchschelle 

# 87011 (919) f hose 

# damp

y Schlauchschelle 87012 (11/9) I hose 

# damp

z Schlauchschelle 870f3 

# (1219) 

# f hose 

# damp



# Ausgabe April 2007

issued April 2007

AM 800-17-07

# iii· 

# »

1111::

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# III

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# cr'cr' 

# 2 2**~ ~**  >-'



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1

2

3

4



# 5

6

7



# 8



# 9

10

11

12

13

14

15

24 

# 8RU7 8R93/2 

# Lenkbares Spornrad mit Nadellagern

steerable tail wheel with needle bearings



# DG BOBC

# :~~ I

# ~ 1_11 Nadellager NA4903 (needle bearing)

Innenringe mit Loctite 638 auf 8R94 verklebt (inner rings secured with Loctite 638 to 8R94)

Nadellager NA4903RS (needle bearing)

WC18DU Splintbolzen (clevispin)

6x18/15 DIN 1434

8R93/3

Dichtung

5.3 DIN125 Stzn

M5 LN9348 DU-Schicht unten

(Einbau vor Montage der

Innenringe Nadellager)

DU-coating on lower side

(install prior to inner rings

of the needle bearings)

4R25 Z162M Zugfeder (spring)

Seitenruderseil

rudder cable

Reifen 20Ox50

lyre Kugelgelagertes

Spomrad S23

hub with

ball bearings

4R89/1

DUCATI-Zilndanlage ISKRA..zOndanlage



# IOUCATI·Ignltion svstem) (ISKRA.Jgnltlon svstem)

Schraube (bolt) MS

... 12 DIN 912-8.Bzn 

# Schraube (bolt) MB.12 DIN 912-8,8zo

Scheibe (washer) 8.4 DIN 125 Stzn

# Scheibtlwash~£>- 8,4 DIN 12551 zn 

# RM275/3

# ~

Sc:hraube (bolt) M8:><25 DIN 912-8.8zo Schraube (boll)**MB~30** 

# DIN 912-8.8zn 

# 6,4 DIN 125 Stzn

6,4 DIN 9021Stzn

Splint 1,5x12 DIN 94

splitspin

S23

4R89/2

# //~~~ 

# ·0/ 4R89/1

Scheibe (washer)8,4 DIN 125 Stzn Scheibe (washer) 8,4 DIN 125 51 zn



# Buchse bush B M 277 Buchse bush 4 M 16/2

Splinlbolzen (clevis pin) 6)(16

... 3,5 DIN 1434 Stzn 

# '-.. iffi?iJ<;- //

Scheibe (washer) 6,4 DIN 125 51 zn

S lint solit 

# Din 1,6)<10 DIN 94

BM27912



# 8M2BO



# --

--

Schraube (boll) M6x35 DIN 931-B.Bzn

Scheibe (washer) 6,4 DIN 125 51 zn

Mutter (nul) M6 DIN 934-8 zn

Gummiseil rubber band) ",2mm, 6-fach

Schraube (boll) M4,16 DIN 933·8.8 SI zn

Buchse (bush) 8M74/3

Schraube (bolt) MBxi0 DIN 933-B.8zn

Kepf auf Hohe von 4,5mm abgedreht

bollhead turned d0'M110 4.Smm)

Schraube (bolt) M6x30 DIN 9i2-8.8zn

# ~Xu~t~~~~~di;~~~e~:~~:nDIN 125 Slzn

Stellschraube ad'ustment screw M6x20 /20

Mutter nut M6 DIN 936-8zn

Klemmnippel set screw clamp) 2-37 6x13

Bremsbelao brake Ifninol BM277/2 Identfsch (identical)

BM27911



# BM273



# BM27811

Schraube (bolt) M6K16 DIN 912-8.8zn

ScheibEU..washe!L6,4 DIN 125 Slzn

Schraube (boll) M4x16 DIN 933-B.Bzn

Scheibe (washer) B,4 DIN 9021 SI zn

Buchs. (bush) B M 7413

Zuafeder lension sorinQ) 1,2x9)(16

Schraube (bolt) M4,16 DIN 933-!l.Bzn

Scheibe (washer) B,4 DIN 9021 SI zn

Buchstibus11LB M 7412

Schraube (bolt) MBx12 DIN 912-B.8zn

Scheibe (washer) 8,4 DIN 125 SI zn

identlsch (identical)

identisch identical

idenlisch idenlical

idenUsch Identical)

Bremsbela brake linin BM275/2



# Anmerlnmg: Anstelle des

# ~. 

# "

J;

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# ~ 

# e

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# -",**§~**



# ::r. "**~** 

# 2-



# Ti

Bremsmalor {Progetlerbrake malor}: 

# Bremshcbels 8M275/J kann cin**~** 

# <:-

# ~ 

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1iJ Ictirzerc Hebel 8M287/1 

# mit 16 Schraube (boll)**M3~16** 

# DIN 84 MS

# ~)(U~I~~~~)(~~~~e;1:.~~IN 125 MS 

# verschraubtcm Belag 8M287/3



# verwendel werden. Der

# ~i

17 Schraube (ball) M5)(25 DIN 7984-B.Bzn 

# Splintbelzen 3 is! von vorn nach

Scheibe (washerI5.3 DIN 125 SIzn

lB Schraube (batt) M5",25 DIN 912-8.Bzn 

# hinten ZU 

# lUOnUeren.

Scheibe

# (wa5he~1· 5.3 DIN 125 Slzn 

# Note: Instead of the brake lever

19 Lothulse soldered cap) M4 

# 8M275/1 a shorter lever

20 Gabelkopf fork end M4 

# 8M287/1 with screw on brake 21 Bawdenzughulle 05mm mit Teflonlnnenhulle 

# Jlrems"'otor

Bomen outer 05mm plaled inside with teflon 

# pad 8M287/3 

# may be used. The

22 BowdenzuQ IbalNden inner 01.5mm 

# split pin 3 must be installed

23 Halteruno bracket BR212 

# from Ule front. 

# 'Propellerbrc<k. Motor

Zeichnung fOr ISKRA-Zundanlage (Drawing for ISCRA-ignition system) 

# o**~.** 

# iiJ

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# M6x20 DIN933-B.B



# z

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# top view

Teflon-plate 2mm thick

between 6FW17 and 6FW12

BFVWJ2

i

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# \m**(\~-/\-----;:'~};I,iJ-----------~---~3"-** 

# .

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# c..

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# notched taper pin

3x20 DIN 1471 

# Detail Z

BFW9/5 BFW9/4

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6.4DIN125S1zn

M6DIN985-8 

# zn



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# lmm.~~~iChenJng FW27

6,4 DIN9021Stzn 

# '"

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# ~ FW2411

FW2412 IM6 DIN439 B

M6 x 45 DIN931-B.B



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